Operating Instructions: Diesel Engine 8 V 2000 M72 10 V 2000 M72

Operating Instructions
Diesel engine
8 V 2000 M72
10 V 2000 M72
M015630/04E
Printed in Germany
© 2012 Copyright MTU Friedrichshafen GmbH
This Publication is protected by copyright and may not be used in any way whether in whole or in part without the prior
written permission of MTU Friedrichshafen GmbH. This restriction also applies to copyright, distribution, translation, micro‐
filming and storage or processing on electronic systems including data bases and online services.
This handbook is provided for use by maintenance and operating personnel in order to avoid malfunctions or damage
during operation.
Subject to alterations and amendments.
Commissioning Note
Important
Please complete and return the “Commissioning Note” card below to MTU Friedrichshafen GmbH.
The Commissioning Note information serves as a basis for the contractually agreed logistic support (war‐
ranty, spare parts, etc.).
Table of Contents
1 Safety 4.5 Fuel treatment system – Putting into
operation 61
1.1 General conditions 7 4.6 Starting the engine 63
1.2 Personnel and organizational requirements 8 4.7 Fuel treatment system – Switching on 64
1.3 Transport 9 4.8 Operational checks 65
1.4 Safety regulations for startup and operation 11 4.9 Stopping the engine 66
1.5 Safety regulations for maintenance and 4.10 Emergency stop 67
repair work 12 4.11 After stopping the engine 68
1.6 Auxiliary materials, fluids and lubricants, 4.12 Fuel treatment system – Shutdown 69
fire prevention and environmental 4.13 Plant cleaning 70
protection 15
1.7 Conventions for safety instructions in the
text 17
5 Maintenance
5.1 Maintenance task reference table [QL1] 71
2 General Information
2.1 Tightening specifications for screws, nuts
and bolts 18 6 Troubleshooting
2.2 Engine side and cylinder designations 29
6.1 Fuel treatment system – Troubleshooting 72
2.3 Product description 30
6.2 Troubleshooting 73
2.4 Engine layout 36
2.5 Sensors, actuators and injectors –
Overview 38
7 Task Description
7.1 SOLAS 76
3 Technical Data 7.1.1 Installation locations for SOLAS shielding 76
7.1.2 SOLAS shielding – Installation as per MTN
3.1 8V 2000 M72 engine data : Separate heat 5233 82
exchanger 43
3.2 8V 2000 M72 engine data: Engine- 7.2 Engine 83
mounted heat exchanger 46 7.2.1 Engine – Barring manually 83
3.3 10V 2000 M72 engine data: Separate heat 7.2.2 Engine – Barring with starting system 84
exchanger 49 7.3 Cylinder Liner 85
3.4 10V 2000 M72 engine data: Engine- 7.3.1 Cylinder liner – Endoscopic examination 85
mounted heat exchanger 52 7.3.2 Cylinder liner – Instructions and comments on
3.5 Firing order 55 endoscopic and visual examination 87
3.6 Engine – Main dimensions 56
7.4 Crankcase Breather 89
7.4.1 Crankcase breather – Cleaning oil pre-
separator element 89
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4 Operation 7.4.2 Crankcase breather – Oil separator element

replacement, diaphragm check and
4.1 Engine – Putting the engine into operation replacement 90
(out of service > 3 months) 57
4.2 Putting the engine into operation after 7.5 Valve Drive 92
scheduled out-of-service period 58 7.5.1 Valve clearance – Check and adjustment 92
7.5.2 Cylinder-head cover – Removal and
4.3 Tasks after extended out-of-service periods
installation 95
(>3 weeks) 59
4.4 Checks prior to start-up 60 7.6 Injection Valve / Injector 96
7.6.1 Injector – Replacement 96
M015630/04E 2012-07 | Table of Contents | 5

7.6.2 Injector – Removal and installation 97 7.17.1 Drive belt – Condition check 133
7.7 Fuel System 99 7.18 Battery-Charging Generator 134

7.7.1 Fuel system – Venting 99 7.18.1 Battery-charging generator drive – Drive belt
check and adjustment 134
7.8 Fuel Filter 100 7.18.2 Battery-charging generator drive – Drive belt
7.8.1 Fuel filter – Replacement 100 replacement 136
7.8.2 Fuel prefilter – Differential pressure check and
adjustment of gauge 102 7.19 Fuel Supply System 137
7.8.3 Fuel prefilter – Draining 103 7.19.1 Water drain valve – Check 137
7.8.4 Fuel prefilter – Flushing 104 7.19.2 Differential pressure gauge – Check 138
7.8.5 Fuel prefilter – Filter element replacement 106 7.19.3 Water level probe (3-in-1 rod electrode) –
Check 139
7.9 Charge-Air Cooling 108 7.19.4 Pump capacity – Check 140
7.9.1 Intercooler – Checking condensate drain line 7.19.5 Coalescer filter element – Replacement 141
for coolant discharge and obstruction 108
7.20 Wiring (General) for Engine/Gearbox/Unit 143
7.10 Air Filter 109 7.20.1 Engine wiring – Check 143
7.10.1 Air filter – Replacement 109
7.10.2 Air filter – Removal and installation 110 7.21 Accessories for (Electronic) Engine
Governor / Control System 144
7.11 Air Intake 111 7.21.1 Engine governor and connectors – Cleaning 144
7.11.1 Contamination indicator – Signal ring position 7.21.2 Engine monitoring unit and connectors –
check (optional) 111 Cleaning 145
7.21.3 Engine governor – Checking plug-in
7.12 Starting Equipment 112
connections 146
7.12.1 Starter – Condition check 112
7.21.4 Engine monitoring unit – Plug connection
7.13 Lube Oil System, Lube Oil Circuit 113 check 147
7.13.1 Engine oil – Level check 113 7.21.5 Engine governor – Carry out self-test 148
7.13.2 Engine oil – Change 114 7.21.6 ECU 7 engine governor – Removal and
installation 149
7.14 Oil Filtration / Cooling 115 7.21.7 Engine monitoring unit – Removal and
7.14.1 Engine oil filter – Replacement 115 installation 150
7.14.2 Centrifugal oil filter – Cleaning and filter-
sleeve replacement 117
7.15 Coolant Circuit, General, High-

Temperature Circuit 120 8 Appendix A
7.15.1 Drain and venting points 120
8.1 Abbreviations 151
7.15.2 Engine coolant – Level check 125
8.2 Standard tools – Overview 154
7.15.3 Engine coolant – Change 126
7.15.4 Engine coolant – Draining 127
8.3 MTU contact persons/service partners 155
7.15.5 Engine coolant – Filling 128
7.15.6 HT coolant pump — Relief bore check 129
7.15.7 Engine coolant – Sample extraction and
9 Appendix B
analysis 130
7.15.8 Coolant filter – Replacement 131 9.1 Special Tools 156
7.16 Raw Water Pump with Connections 132 9.2 Consumables 163
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7.16.1 Raw water pump – Relief bore check 132 9.3 Spare Parts 165
9.4 Index 167
7.17 Belt Drive 133
6 | Table of Contents | M015630/04E 2012-07

1 Safety
1.1 General conditions
General
In addition to the instructions in this publication, the applicable country-specific legislation and other com‐
pulsory regulations regarding accident prevention and environmental protection must be observed. This
state-of-the-art engine has been designed to meet all applicable laws and regulations. The engine may
nevertheless present a risk of injury or damage in the following cases:
• Incorrect use
• Operation, maintenance and repair by unqualified personnel
• Modifications or conversions
• Noncompliance with the Safety Instructions
Correct use
The engine is intended solely for use in accordance with contractual agreements and the purpose envis‐
aged for it on delivery. Any other use is considered improper use. The engine manufacturer accepts no
liability whatsoever for resultant damage or injury in such case. The responsibility is borne by the user
alone.
Correct use also includes observation of and compliance with the maintenance specifications.
Modifications or conversions
Unauthorized modifications to the engine represent a safety risk.
MTU will accept no liability or warranty claims for any damage caused by unauthorized modifications or
conversions.
Spare parts
Only genuine MTU spare parts must be used to replace components or assemblies. MTU accepts no
liability whatsoever for damage or injury resulting from the use of other spare parts and the warranty shall
be voided in such case.
Reworking components
Repair or engine overhaul must be carried out in workshops authorized by MTU.
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M015630/04E 2012-07 | Safety | 7

1.2 Personnel and organizational requirements
Personnel requirements
All work on the engine shall be carried out by trained and qualified personnel only.
The specified legal minimum age must be observed.
The operator must specify the responsibilities of the operating, maintenance and repair personnel.
Organizational measures
This publication must be issued to all personnel involved in operation, maintenance, repair or transporta‐
tion.
Keep it at hand at the operating site of the engine so that it is available to operating, maintenance, repair
and transport personnel at all times.
Use the manual as a basis for instructing personnel on engine operation and repair with an emphasis on
explaining safety-relevant instructions.
This is particularly important in the case of personnel who only occasionally perform work on or around
the engine. This personnel must be instructed repeatedly.
For the identification and layout of the spare parts during maintenance or repair work, take photos or use
the spare parts catalog.
Working clothes and protective equipment

Wear proper protective clothing for all work.
Use the necessary protective equipment for the given work to be done.
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8 | Safety | M015630/04E 2012-07

1.3 Transport
Transport without flange-mounted gearbox
A Max. permissible diago‐

nal pull: 35°
Illustration is applicable to 8/10V 2000M engines
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M015630/04E 2012-07 | Safety | 9

Transport with flange-mounted gearbox
Illustration is applicable to 8/10V 2000M engines

Only use the lifting eyes provided to lift the engine.
The eyebolts mounted at the driving end and on the gearbox must not be used for transporting plants
with flange-mounted gearboxes.
Only use transport and lifting devices approved by MTU.
Take the engine's center of gravity into account.
The engine must only be transported in installation position, max. permissible diagonal pull with flanged-
on gearbox is 10°.
If the engine is supplied with special aluminium foil packing, lift the engine at the lifting eyes of the bear‐
ing pedestal or use a means of transportation which is appropriate for the given weight (forklift truck).
Install the crankshaft locking device and the locking screws for the engine mounts prior to engine trans‐
portation.
Secure the engine against tilting during transport. In particular when going down inclines or ramps, the
engine must be secured against moving and tilting.
Setting the engine down after transport

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Only set down engine on a firm, level surface.

Make sure that the consistency and load-bearing capacity of the ground or support surface is adequate.
Never set an engine down on the oil pan unless expressively authorized to do so by MTU on a case-to-
case basis .
10 | Safety | M015630/04E 2012-07

1.4 Safety regulations for startup and operation
Safety precautions when putting the equipment into operation

Prior to initial operation of the assembly or plant, install the assembly or unit according to the specifica‐
tions and check the installation according to the MTU specifications.
Before putting the device or plant into operation, always ensure:
• that all maintenance and repair work is completed,
• that all loose parts have been removed from rotating machine components,
• that all persons are clear of the danger zone of moving machine components.
Immediately after putting the device or plant into operation, make sure that all control and display instru‐
ments as well as the monitoring, signaling and alarm systems are working properly.
Safety regulations for equipment operation

Emergency procedures must be practiced regularly.
The operator must be familiar with the controls and displays.
The operator must be familiar with the consequences of all operations to be performed.
During operation, the display instruments and monitoring units must be permanently observed with re‐
gard to present operating status, violation of limit values and warning or alarm messages.
The following steps must be taken if a malfunction of the system is recognized or reported by the system:
• inform supervisor(s) in charge,
• analyze the message,
• if required, carry out emergency operations e.g. emergency engine stop.
Engine operation
The following conditions must be fulfilled before starting the engine:
• Wear ear protectors.
• Ensure that the engine room is well ventilated.
• Do not inhale engine exhaust gases.
• Ensure that the exhaust system is free of leaks and that the gases are discharged to atmosphere.
• Mop up any leaked or spilled fluids and lubricants immediately or soak up with a suitable binding
agent.
• Protect battery terminals, battery-charger terminals and cables against accidental contact.
• When the engine is running, never release coolant, oil, fuel, compressed-air or hydraulic lines.
Operation of electrical equipment

When operating electrical equipment, certain components of this equipment are live.
Observe the safety instructions for these devices.
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M015630/04E 2012-07 | Safety | 11

1.5 Safety regulations for maintenance and repair work
Safety regulations for maintenance and repair work

Have maintenance and repair work carried out by qualified and authorized personnel only.
Allow the engine to cool down before starting maintenance work (risk of explosion of oil vapors).
Before starting work, relieve pressure in systems and compressed-air lines which are to be opened.
Take special care when removing ventilation or plug screws from the engine. Cover the screw or plug
with a rag to prevent fluids escaping under pressure.
Take special care when draining hot fluids ⇒ Risk of injury.
When changing the engine oil or working on the fuel system, ensure that the engine room is adequately
ventilated.
Allow the engine / system to cool down before starting to work.
Observe the maintenance and repair instructions.
Never carry out maintenance and repair work with the engine running unless expressly instructed to do
so.
Secure the engine against accidental starting.
Disconnect the battery when electrical starters are fitted.
Close the main valve on the compressed-air system and vent the compressed-air line when pneumatic
starters are fitted.
Disconnect the control equipment from the assembly or system.
Use only proper, calibrated tools. Observe the specified tightening torques during assembly/disassembly.
Carry out work only on assembles and/or units which are properly secured.
Never use lines for climbing.
Keep fuel injection lines and connections clean.
Always seal connections with caps or covers if a line is removed or opened.
Take care not to damage lines, in particular fuel lines, during maintenance and repair work.
Ensure that all retainers and dampers are installed correctly.
Ensure that all fuel injection and pressurized oil lines are installed with enough clearance to prevent con‐
tact with other components. Do not place fuel or oil lines near hot components.
Do not touch elastomeric seals if they have carbonized or resinous appearance unless hands are proper‐
ly protected.
Note cooling time for components which are heated for installation or removal ⇒ Risk of burning.
When working high on the engine, always use suitable ladders and work platforms. Make sure compo‐
nents are placed on stable surfaces.
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Observe special cleanness when conducting maintenance and repair work on the assembly or system.
After completion of maintenance and repair work, make sure that no loose objects are in/on the assem‐
bly or system.
Before barring the engine, make sure that nobody is standing in the danger zone. Check that all guards
have been reinstalled and that all tools and loose parts have been removed after working on the engine.
The following additional instructions apply to starters with beryllium copper pinion:
• Breathing protection of filter class P2 must be applied during maintenance work to avoid health haz‐
ards caused by the beryllium-containing pinion. Do not blow out the interior of the flywheel housing or
the starter with compressed air. Clean the flywheel housing inside with a class H dust extraction de‐
vice as an additional measure.
12 | Safety | M015630/04E 2012-07

Welding work
Never carry out welding work on the assembly, system, or engine-mounted units. Cover the engine when
welding in its vicinity.
Do not use the assembly or system as ground terminal.
Do not route the welding lead over or near the wiring harnesses of MTU systems. The welding current
may otherwise induce an interference voltage in the wiring harnesses which could conceivably damage
the electrical system.
Remove parts (e.g. exhaust pipes) which are to be welded from the engine beforehand.
Hydraulic installation and removal

Check the function and safe operating condition of tools and fixtures to be used. Use only the specified
devices for hydraulic removal/installation procedures.
Observe the max. permissible push-on pressure specified for the equipment.
Do not attempt to bend or apply force to lines.
Before starting work, pay attention to the following:
• Vent the hydraulic installation/removal tool, the pumps and the lines at the relevant points for the
equipment to be used (e.g. open vent plugs, pump until bubble-free air emerges, close vent plugs).
• For hydraulic installation, screw on the tool with the piston retracted.
• For hydraulic removal, screw on the tool with the piston extended.
For a hydraulic installation/removal tool with central expansion pressure supply, screw spindle into shaft
end until correct sealing is established.
During hydraulic installation and removal, ensure that nobody is standing in the immediate vicinity of the
component to be installed/removed.
Working on electrical/electronic assemblies

Always obtain the permission of the person in charge before commencing maintenance and repair work
or switching off any part of the electronic system required to do so.
De-energize the appropriate areas prior to working on assemblies.
Do not damage cabling during removal work. When reinstalling ensure that wiring is not damaged during
operation by contact with sharp objects, by rubbing against other components or by a hot surface.
Do not secure cables on lines carrying fluids.
Do not use cable binders to secure cables.
Always use connector pliers to tighten connectors.
Subject the device or system to a function check on completion of all repair work.
Store spare parts properly prior to replacement, i.e. protect them against moisture in particular. Pack de‐
fective electronic components and assemblies in a suitable manner when dispatched for repair, i.e. par‐
ticularly protected against moisture and impact and wrapped in antistatic foil if necessary.
Working with laser equipment

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When working with laser equipment, always wear special laser-protection goggles ⇒ Heavily focused ra‐
diation.
Laser equipment must be fitted with the protective devices necessary for safe operation according to
type and application.
M015630/04E 2012-07 | Safety | 13

For conducting light-beam procedures and measurement work, only the following laser devices must be
used:
• Laser devices of classes 1, 2 or 3A.
• Laser devices of class 3B, which have maximum output in the visible wavelength range (400 to 700
nm), a maximum output of 5 mW, and in which the beam axis and surface are designed to prevent
any risk to the eyes.
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14 | Safety | M015630/04E 2012-07

1.6 Auxiliary materials, fluids and lubricants, fire prevention and
environmental protection
Fire prevention
Rectify any fuel or oil leaks immediately; even splashes of oil or fuel on hot components can cause fires –
therefore always keep the engine in a clean condition. Do not leave cloths soaked with fluids and lubri‐
cants lying on or near the assembly or unit. Do not store inflammable material near the assembly or unit.
Do not weld pipes and components carrying oil or fuel! Before welding, clean with a nonflammable fluid.
When starting the engine with an external power source, connect the ground lead last and remove it first.
To avoid sparks in the vicinity of the battery, connect the ground lead from the external power source to
the ground lead of the engine or to the ground terminal of the starter.
Always keep suitable firefighting equipment (fire extinguishers) at hand and familiarize yourself with their
use.
Noise
Noise can lead to an increased risk of accident if acoustic signals, warning shouts or noises indicating
danger are drowned.
Wear ear protectors in work areas with a sound pressure level in excess of 85 dB (A).
Environmental protection and disposal

Modification or removal of mechanical or electronic components or the installation of additional compo‐
nents as well as the execution of calibration processes that might affect the emission characteristics of
the engine are prohibited by emission regulations. Emission control units/systems may only be main‐
tained, exchanged or repaired if the components used for this purpose are approved by MTU or equiva‐
lent components. Noncompliance with these guidelines might represent a violation of the Clean Air Act
and involves the termination of the operating license by the emission authorities. MTU does not accept
any liability for violations of the emission regulations. MTU will provide assistance and advice if emission-
relevant components are intended to be modified. The MTU Maintenance Schedules ensure the reliabili‐
ty and performance of MTU engines and must be complied with over the entire life cycle of the engine.
Use only fuel of prescribed quality to comply with emission limit values.
Dispose of used fluids, lubricants and filters in accordance with local regulations.
Within the EU, batteries can be returned free of charge to MTU FN / MTU Onsite Energy where they are
subjected to proper recycling procedures.
Auxiliary materials, fluids and lubricants

Use only fluids and lubricants that have been tested and approved by MTU.
The Fluids and Lubricants Specifications will be amended or supplemented as necessary. Before using
them, make sure you have the latest version. The latest version is also available at: http://www.mtu-on‐
line.com/mtu/mtu-valuecare/mtu-valueservice-Technische-Dokumentation.
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Keep fluids and lubricants in suitable, properly designated containers. When using fluids, lubricants and
other chemical substances, follow the safety instructions that apply to the product. Take special care
when using hot, chilled or caustic materials. When using flammable materials, avoid all sparks and do
not smoke.
Used oil
Used oil contains harmful combustion residues.
Rub barrier cream into hands.
Wash hands after contact with used oil.
M015630/04E 2012-07 | Safety | 15

Lead
• When working with lead or lead-containing compounds, avoid direct contact to the skin and do not
inhale lead vapors.
• Adopt suitable measures to avoid the formation of lead dust.
• Switch on extraction system.
• Wash hands after contact with lead or lead-containing substances.
Compressed air
Observe special safety precautions when working with compressed air:
• Pay special attention to the pressure level in the compressed air network and pressure vessel.
• Assemblies and equipment to be connected must either be designed for this pressure, or, if the per‐
mitted pressure for the connecting elements is lower than the pressure required, a pressure reducing
valve and safety valve (set to permitted pressure) must form an intermediate connection.
• Hose couplings and connections must be securely attached.
• Wear goggles when blowing off components or blowing away chips.
• Provide the snout of the air nozzle with a protective disk (e.g. rubber disk).
• First shut off compressed air lines before compressed air equipment is disconnected from the supply
line, or before equipment or tool is to be replaced.
• Unauthorized use of compressed air, e.g. forcing flammable liquids (danger class AI, AII and B) out of
containers, results in a risk of explosion.
• Forcing compressed air into thin-walled containers (e.g. containers made of tin, plastic and glass) for
drying purposes or to check for leaks, results in a risk of bursting.
• Carry out leak test in accordance with the specifications.
Paints and lacquers

• When carrying out painting work outside the spray stands provided with fume extraction systems, en‐
sure that the area is well ventilated. Make sure that neighboring work areas are not impaired.
• No open flames.
• No smoking.
• Observe fire prevention regulations.
• Always wear a mask providing protection against paint and solvent vapors.
Liquid nitrogen
• Store liquid nitrogen only in small quantities and always in regulation containers without fixed covers.
• Avoid body contact (eyes, hands).
• Wear protective clothing, protective gloves, closed shoes and protective goggles / safety mask.
• Make sure that working area is well ventilated.
• Avoid all knocks and jars to the containers, fixtures or workpieces.
Acids and alkaline solutions

• When working with acids and alkaline solutions, wear protective goggles or face mask, gloves and
protective clothing.
• If such solutions are spilled onto clothing, remove the affected clothing immediately.
• Rinse injured parts of the body thoroughly with clean water.
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• Rinse eyes immediately with eyedrops or clean tap water.
16 | Safety | M015630/04E 2012-07

1.7 Conventions for safety instructions in the text
DANGER
In the event of immediate danger.
Consequences: Death or serious injury
• Remedial action
WARNING
In the event of potentially dangerous situations.
Consequences: Death or serious injury
• Remedial action
CAUTION
In the event of dangerous situations.
Consequences: Minor injury or material damage
• Remedial action
NOTICE
In the event of a situation involving potentially adverse effects on the product.
Consequences: Material damage.
• Remedial action
• Additional product information
Note: This manual contains highlighted safety warnings in accordance with the US ANSI Z535 standard which
begin with one of the signal words listed above depending on the severity of the hazard.
Safety instructions
1. Read and familiarize yourself with all safety notices before starting up or repairing the product.
2. Pass on all safety instructions to your operating, maintenance, repair and transport personnel.
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M015630/04E 2012-07 | Safety | 17

2 General Information
2.1 Tightening specifications for screws, nuts and bolts
Tightening torques for setscrew and stud joints as per MTN 5008 standard
This works standard applies to setscrews subjected to little dynamic load as per MMN 384, DIN 912, EN
24014 (DIN 931-1), EN 24017 (DIN 933), EN 28765 (DIN 960), EN 28676 (DIN 961), DIN 6912 and to
studs as per DIN 833, DIN 835, DIN 836, DIN 938, DIN 939 and associated nuts.
It does not apply to heat-resistant screws in the hot component area.
Tightening torques MA are specified for screws of strength class 8.8 (surface condition bare, phosphat‐
ized or galvanized) and 10.9 (surface condition bare or phosphatized).
The values given in the table are based on a friction coefficient µtot.= 0.125. Prerequisite: Threads and
mating faces of screws and nuts must be lubricated with engine oil prior to assembly.
When tightening manually (tightening specifications), an assembly tolerance of +10% of the table values
is permitted for unavoidable deviations of the tightening torque from the table value during the tightening
process – e.g. resulting from inaccurate readings and overtightening during assembly.
When machine-tightening, the permissible assembly tolerance is +15 %.
Hand-tightening Machine-tightening
Thread
8.8 MA (Nm) 10.9 MA (Nm) 8.8 MA (Nm) 10.9 MA (Nm)
M6 9 12 8 11
M8 21 31 20 28
M8 x 1 23 32 21 30
M10 42 60 40 57
M10 x 1.25 45 63 42 60
M12 74 100 70 92
M12 x 1.25 80 110 75 105
M12 x 1.5 76 105 72 100
M14 115 160 110 150
M14 x 1.5 125 180 120 170
M16 180 250 170 235
M16 x 1.5 190 270 180 255
M18 250 350 240 330
M18 x 1.5 280 400 270 380
M20 350 500 330 475
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M2 x 1.5 390 550 350 520

M22 480 680 450 650
M22 x 1.5 520 730 490 700
M24 600 850 570 810
M24 x 1.5 680 950 640 900
M24 x 2 660 900 620 850
M27 900 1250 850 1175
18 | General Information | M015630/04E 2012-07

Hand-tightening Machine-tightening
Thread
8.8 MA (Nm) 10.9 MA (Nm) 8.8 MA (Nm) 10.9 MA (Nm)
M27 x 2 960 1350 900 1275
M30 1200 1700 1100 1600
M30 x 2 1350 1900 1250 1800
MA= tightening torques
Tightening torques for stress bolt connections as per MTN 5007 standard
This standard applies to statically and dynamically loaded stress bolt connections of strength class 10.9
and for corresponding nuts.
Shaft and transition dimensions as per MMN 209 standard and material and machining as per MMN 389
standard (bright surface or phosphatized).
The values given in the table are based on a friction coefficient µtot.= 0.125. Prerequisite: Threads and
mating faces of screws and nuts must be lubricated with engine oil prior to assembly.
When tightening manually (defined tightening), an assembly tolerance of +10 % of the table values is
permitted for unavoidable deviations of the tightening torque from the table value during the tightening
The values in the tables are for manual tightening using a torque wrench.
Thread Not torsion-protected MA(Nm) Torsion-protected MA(Nm)
M6 9 12
M8 21 28
M8 x 1 24 30
M10 42 55
M10 x 1.25 46 60
M12 75 93
M12 x 1.5 78 99
M14 120 150
M14 x 1.5 135 160
M16 180 225
M16 x 1.5 200 245
M18 250 315
M18 x 1.5 300 360
M20 350 450
M20 x 1.5 430 495
M22 500 620
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M22 x 1.5 560 675

M24 640 790
M24 x 2 700 850
M27 900 1170
M27 x 2 1000 1230
M30 1250 1575
*Protect screw shank against torsion when tightening.
M015630/04E 2012-07 | General Information | 19

Tightening torques for plug screws as per MTN 5183-1 standard

This standard applies to plug screws as per DIN 908, DIN 910 and DIN 7604 with screwed plug
DIN 3852 shape A (sealed by sealing ring DIN 7603-Cu).
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Tightening torques MA are given for plug screws made of steel (St) with phosphatized surface-protection
and oiled or galvanized. Thread and mating faces beneath heads must be coated in engine oil prior to
assembly. When tightening manually (defined tightening), an assembly tolerance of +10 % of the table
values is permitted for unavoidable deviations of the tightening torque from the table value during the
tightening process – e.g. resulting from inaccurate readings and overtightening during assembly.
Tightening torques for plug screws DIN 908, DIN 910 and DIN 7604A (with short screwed plug).
Screwed into
Thread Steel/gray cast iron MA AI alloy MA
(Nm) (Nm)
M10 x 1 15 15
M12 x 1.5 30 25
M14 x 1.5 35 30
M16 x 1.5 40 35
M18 x 1.5 50 40
M20 x 1.5 60 50
M22 x 1.5 70 70
M24 x 1.5 85 80
M26 x 1.5 100 100
M27 x 2 100 100
M30 x 1.5 110 110
M30 x 2 120 120
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M33 x 2 160 160

M36 x 1.5 190 180
M38 x 1.5 220 200
M42 x 1.5 260 240
M45 x 1.5 290 270
M48 x 1.5 310 *300
M52 x 1.5 325 320

Screwed into
(Nm) (Nm)
M56 x 2 380 360
M64 x 2 400 400
Tightening torques for plug screws DIN 7604C (with long screwed plug)
Screwed into
Thread Steel/gray cast iron MA Al alloy MA
(Nm) (Nm)
M8 x 1 10 10
M22 x 1.5 80 65
M26 x 1.5 105 90
M30 x 1.5 130 130
M38 x 1.5 140 120
M45 x 1.5 160 140
Tightening torques for banjo screws as per MTN 5183-2 standard

This standard applies to banjo screws as per MMN 223 and N 15011 sealed with sealing ring DIN 7603-
Cu.
TIM-ID: 0000002333 - 010

The stated tightening torques MA apply to steel (St) banjo screws with a phosphatized surface and oiled
or galvanized and for copper-aluminum alloy.
Thread and mating faces beneath heads must be coated with engine oil prior to assembly.
Tightening torques for steel banjo screws

Screwed into steel/gray cast iron/Al alloy MA
Thread
(Nm)
M8 x 1 10
M10 x 1 15
M12 x 1.5 20
M14 x 1.5 25
M16 x 1.5 25
M18 x 1.5 30
M22 x 1.5 60
M26 x 1.5 90
M30 x 1.5 130
M38 x 1.5 140
M45 x 1.5 160
TIM-ID: 0000002333 - 010
Tightening torques for copper-aluminum alloy banjo screws

Screwed into steel/gray cast iron/Al alloy MA
Thread
(Nm)
M10 x 1 15
M16 x 1.5 30

Tightening torques for male connectors as per MTN standard 5183-3
This standard applies to male connectors DIN 2353, L series, with screwed plug DIN 3852, model A
(sealed by sealing ring DIN 7603-Cu).
Tightening torques MA are given for male connectors made of steel (St) with surface protected by a phos‐
phate coating and oiled or galvanized.
Thread and mating faces beneath heads must be coated with engine oil prior to assembly.
Screwed into steel/gray cast iron MA
Thread
(Nm)
M10 x 1 15
M12 x 1.5 20
M14 x 1.5 35
M16 x 1.5 50
M18 x 1.5 60
M22 x 1.5 70
M26 x 1.5 100
M32 x 2 160
M42 x 2 260
M48 x 2 320
TIM-ID: 0000002333 - 010

Tightening torques for union nuts as per DIN 3859-2
1 Union nut
2 Screw fixture
3 O-ring
4 Linear ball bearing
Union nut: When installing the linear ball bearing, after firm hand-tightening (noticeable increase in force)
the union nut is further tightened by a quarter of a rotation (90°) beyond this point.
Tightening torques for screwed plugs with O-ring as per ISO 6149-2
Thread Torque (Nm) + 10%

M8 x 1 10
TIM-ID: 0000002333 - 010
M10 x 1 20
M12 x 1.5 35
M14 x 1.5 45
M16 x 1.5 55
M18 x 1.5 70
M20 x 1.5 1) 80
M22 x 1.5 100

M27 x 2 170
M33 x 2 310
M42 x 2 330
M48 x 2 420
M60 x 2 500
1)
Only for closing off installation spaces for screw-in valves (see ISO 7789)
Tightening torques for screwed plugs with O-ring as per ISO 6149-3

M8 x 1 8
M10 x 1 15
M12 x 1.5 25
M14 x 1.5 35
M16 x 1.5 40
M18 x 1.5 45
M22 x 1.5 60
M27 x 2 100
M33 x 2 160
M42 x 2 210
TIM-ID: 0000002333 - 010
M48 x 2 260
M60 x 2 315

Tightening torques for plug screws as per MTN 5183-6
Screwed into
(Nm) (Nm)
M10 x 1 20 10+ 2
M12 x 1.5 35 14+ 2
M14 x 1.5 45 15+ 3
M16 x 1.5 55 18+ 3
M18 x 1.5 70 23+ 3
M22 x 1.5 100 33+ 4
M27 x 2 170 57+ 5
M33 x 2 310 103+ 10
M42 x 2 330 110+ 11
M48 x 2 420 140+ 14
M60 x 2 1) 200+ 20
1)
Value still to be determined
Assembly instructions and tightening torques for hose fittings with union nuts
In contrast to the instructions for pipe unions, hose fittings with sealing heads and the associated adapt‐
ers must be installed and connected as follows (these instructions do not apply to ORFS fittings).
TIM-ID: 0000002333 - 010
Hose fitting, metallic sealing with union nut: Tighten union nut by hand then tighten a further max. 1/4 of
a revolution with a wrench.
Hose fitting with O-ring and union nut: Tighten union nut by hand then tighten a further max. 1/2 of a
revolution with a wrench.
Hoses must be suitably aligned before tightening the union nuts.

Sealing head/sealing cone with metric union nut
Metric thread Pipe outer dia. Torque (Nm)
M12 x 1.5 6 20
M14 x 1.5 8 38
M16 x 1.5 8 45
10
M18 x 1.5 10 51
12
M20 x 1.5 12 58
M22 x 1.5 14 74
15
M24 x 1.5 16 74
M26 x 1.5 18 105
M30 x 2 20 135
22
M36 x 2 25 166
28
M42 x 2 30 240
M45 x 2 35 290
M52 x 2 38 330
42
Sealing head with BSP union nut

BSPP thread Torque (Nm)
G1/4 20
G3/8 34
G1/2 60
G5/8 69
G3/4 115
G1 140
G1.1/4 210
G1.1/2 290
G2 400
TIM-ID: 0000002333 - 010

2.2 Engine side and cylinder designations
Engine sides are always designated as viewed from the driving end (KS).
The cylinders of the left engine side are designated "A" and those of the right side "B" (as per DIN ISO
1204). The cylinders of each bank are numbered consecutively, starting with No. 1 at the driving end.
Other components are numbered in the same way, i.e. starting with No. 1 on driving end.
1 Left engine side 3 Right engine side

2 KGS = Free end 4 KS = Driving end
TIM-ID: 0000002185 - 010

2.3 Product description
Description of the engine
Engine
The engine is a liquid-cooled four-stroke diesel engine with c.c.w. direction of rotation, direct injection,
sequential turbocharging and charge-air cooling.
An electronic management system provides engine control and monitoring.
Fuel system with common rail injection

Controlled by the engine electronics, the common rail injection system determines injection pressure, in‐
jection timing and injection quantity independently of the engine speed.
Injection pressures up to 1800 bar ensure optimum fuel injection and combustion conditions.
Charging system
The charging system comprises charge-air system, exhaust system and sequential turbocharging.
The exhaust system is equipped with triple-walled, water-cooled exhaust lines.
The triple-walled design permits
• low surface temperature,
• reduced thermal load,
• absolute gas-tightness.
Lube oil system

Wet-sump forced-feed lubrication system
Components supplied with oil:
• Bearings
• Piston cooling
• Control and actuating elements of the sequential turbocharging system
Cooling system
• Two separate cooling circuits:
• Engine coolant
• Raw water
• Coolant cooling by raw water-cooled plate-core heat exchanger
• Thermostat-controlled coolant system
• Coolant-cooled / preheated charge air
• Coolant-cooled fuel return
Electronic system
Electronic control and monitoring system with integrated security and test system with interfaces to re‐
TIM-ID: 0000002177 - 002
mote control system (RCS) and to monitoring system (MCS).
Electronic engine control unit (ECU)

Closed-loop control:
• Engine speed
• Fuel HP

Open-loop control:
• Injection (fuel pressure, injection timing, injection duration, operating status)
• Sequential turbocharging (cutting-in and out) with secondary turbocharger
• Engine protection with multi-stage safety systems:
• Power reduction
• Power limitation
• Emergency stop
Monitoring:
• Exhaust gas temperature, A-side
• Exhaust temperature, B-side
• Engine speed
• Oil pressure
• Differential oil pressure
• Coolant temperature
• Coolant level
• Exhaust turbocharger speed
• Leak fuel level
• Oil temperature
• Coolant pressure
• Fuel pressure after filter
Monitoring in engine room

Engine control and monitoring unit (LOP)
Functions:
• Engine speed, oil pressure and coolant temperature are monitored and displayed
• Integrated safety system
• Integrated test system
• Redundant CAN bus interface to governor and higher-level control and monitoring system
• 24 V DC power supply
TIM-ID: 0000002177 - 002

SOLAS – Fire protection specifications
Special connections
In case of leakage, the above-mentioned connection types are spray-protected even without a cover and
have been confirmed compliant with SOLAS by GL and DNV.
Plug-in pipe connection

The sleeve (4) covers the joint to prevent lateral spray.
TIM-ID: 0000002177 - 002
Only leak-off along the line is possible, the pressure is decreased significantly if an O-ring (3) defect oc‐
curs.
The connection is confirmed as compliant with SOLAS by DNV and GL.
Plugs and sensors

Screw-in plugs (2) are sealed toward the outside either with a copper sealing ring (1), according to DIN,
or an O-ring (ISO).
In case of a loose single-ended union or a defective sealing ring (2), the liquid first has to pass the
thread.

The pressure is so greatly reduced by this and the faulty sealing ring (2) that any leakage is not under
pressure.
HP line between fuel injector and HP accumulator
1 Support ring 4 Union nut 7 Thrust ring

2 V-ring 5 HP line 8 V-ring
3 Thrust ring 6 Thrust screw 9 Support ring
TIM-ID: 0000002177 - 002

HP line between distributor and HP accumulator
1 Union nut 4 Thrust screw 7 Thrust ring

2 O-ring 5 O-ring 8 Pressure pipe
3 Thrust ring 6 O-ring 9 Jacket pipe
TIM-ID: 0000002177 - 002

HP line between distributor and HP accumulator
1 Jacket pipe 5 Thrust screw 9 Pressure pipe

2 O-ring 6 Thrust ring 10 O-ring
3 O-ring 7 O-ring
4 Thrust ring 8 HP line
Leak fuel caused by leakages from the sealing cones or the HP lines is returned to the HP pump, from
where it is routed at atmospheric pressure into a level-monitored leak fuel tank.
TIM-ID: 0000002177 - 002

2.4 Engine layout
1 Engine oil heat ex‐ 14 Exhaust turbocharger, 27 Gearcase

changer left (secondary turbo‐ 28 Raw water pump
2 Engine oil filter charger) 29 Raw water connection
3 Coolant filter 15 Exhaust outlet from sea
4 Diverter lever for engine 16 Crankcase ventilation fil‐ 30 Vibration damper
oil filter ter / Oil separator 31 Engine coolant pump
5 Coolant distribution 17 Actuating cylinder for ex‐ 32 Plate-core heat ex‐
housing with integrated haust flap changer
expansion tank 18 Actuating cylinder for air 33 Raw water connection
6 Fuel cooler flap to sea
7 Engine lifting eye (free 19 Control valve for flap 34 Thermostat housing
end) control 35 Fuel priming pump
8 Air filter with service in‐ 20 Cylinder head cover 36 Fuel duplex filter
dicator 21 Exhaust system housing (switchable)
9 Air inlet 22 Engine mounting KGS = Kraftgegenseite (driv‐
10 Electronic engine man‐ 23 Electric starter ing end)
agement system 24 Oil pan
11 Air collector housing 25 Battery-charging genera‐
(shroud) tor
TIM-ID: 0000002085 - 002
12 Exhaust turbocharger, 26 Raw water connection to

right (primary turbo‐ gearbox cooling system
charger)
13 Carrier housing
Image also applies to 8V2000M72.

1 Crankcase breather 6 Oil filler neck 11 Carrier housing middle
2 Engine lifting eye (driv‐ 7 Oil dipstick section
ing end) 8 Drive flange 12 Carrier housing lower
3 Coolant filler neck 9 Flywheel housing section
4 HP fuel pump 10 Carrier console 13 Wastegate
5 Fuel delivery pump 14 Carrier housing upper
section
KS = Kraftseite (free end)
Image also applies to 8V2000M72.
Engine model designation

Key to the engine model designation 8/10V 2000 M72
8 or 10 Number of cylinders
V Cylinder arrangement: V engine
2000 Series
M Application: M= Marine
7 Load profile (0, 1, 2,..., 9)
2 Design index (0, 1, 2,..., 9)
TIM-ID: 0000002085 - 002

2.5 Sensors, actuators and injectors – Overview
Top view
No. Description Monitoring of

1 B10 Charge-air pressure
2 B9 Charge-air temperature
3 B7 Lube oil temperature
4 B3 Intake air temperature TIM-ID: 0000008375 - 002

Free end

1 B34 Fuel line pressure after filter
2 B5.3 (option) Lube oil pressure before filter
3 B5.1 Lube oil pressure
4 B5.2 (optional) Lube oil pressure
5 F33 Coolant level
6 B21 (optional) Raw water pressure
7 B6.2 (optional) Coolant pressure
8 B6.1 Coolant temperature
TIM-ID: 0000008375 - 002

Driving end

1 B4.22 Exhaust temperature, B-side
2 B1 Camshaft speed
3 B13.1 Crankshaft speed
4 B13.2 (option) Crankshaft speed
5 B4.21 Exhaust gas temperature, A side
TIM-ID: 0000008375 - 002

Right engine side

1 B44 Turbocharger speed
2 B33 Fuel temperature
3 B48 Fuel pressure in Common Rail
4 B16 (optional) Coolant pressure
5 F46 Leak fuel level
TIM-ID: 0000008375 - 002

Left engine side

1 Y41 Wastegate solenoid valves
6 Y27 Solenoid valves for turbocharger control
7 B54 (optional) Oil replenishment pump pressure
System sensors
The sensors are fitted on the off-engine system.
Description Monitoring of
B19 Starting-air pressure
B70 Water level in fuel prefilter
B41 Exhaust backpressure
S37 Start interlock, switching status
TIM-ID: 0000008375 - 002

3 Technical Data
3.1 8V 2000 M72 engine data : Separate heat exchanger
Explanation:
DL Ref. value: Continuous power
BL Ref. value: Fuel stop power (FSP)
A Design value
G Guaranteed value
R Guideline value
L Limit value, up to which the engine can be operated, without change (e.g. of power setting)
N Not yet defined value
- Not applicable
X Applicable
REFERENCE CONDITIONS
Engine model 8V
2000
M72
Application group 1B
Intake air temperature °C 25
Raw water inlet temperature °C 25
Barometric pressure mbar 1000
Site altitude above sea level m 100
POWER RELATED DATA (power ratings are net brake power to ISO 3046)
Number of cylinders 8
Engine rated speed A rpm 2250
Fuel stop power ISO 3046 A kW 720
GENERAL CONDITIONS (for maximum power)

Intake air depression (new filter) A mbar 15
Intake air depression, max. L mbar 30
MODEL RELATED DATA (basic design)

TIM-ID: 0000002882 - 001
Cylinder configuration: V angle degree 90
Bore mm 135
Stroke mm 156
Cylinder displacement liter 2.23
Total displacement liter 17.84
Number of inlet valves, per cylinder 2
Number of exhaust valves, per cylinder 2
M015630/04E 2012-07 | Technical Data | 43

LUBE-OIL SYSTEM
Lube-oil operating temperature before engine, from R °C 82
Lube-oil operating temperature before engine, to R °C 90
Lube-oil operating pressure before engine, from R bar 8.5
Lube-oil operating pressure before engine, to R bar 9.5
Lube-oil operating pressure, low idle (meas. point: before engine) R bar 2.5
FUEL SYSTEM
Fuel pressure at fuel feed connection, min. (when engine is starting) L bar -0.3
Fuel pressure at fuel feed connection, min. (when engine is running) L bar -0.3
Fuel pressure at fuel feed connection , max. (when engine is starting) L bar +0.25
Fuel supply flow, max. R liter/min 3.2
GENERAL OPERATING DATA

Firing speed, from R rpm 100
Firing speed, to R rpm 120
STARTING (electric)
Rated starter voltage (standard design) R V= 24
INCLINATIONS, STANDARD OIL SYSTEM (Reference: waterline)

Longitudinal inclination, continuous max., driving end down (Option: max. L degree 15
operating inclinations)
Longitudinal inclination, temporary max., driving end down (Option: max. L degree 20
Longitudinal inclination, continuous max., driving end up (Option: max. op‐ L degree 0
erating inclinations)
Longitudinal inclination, temporary max., driving end up (Option: max. oper‐ L degree 10
ating inclinations)
Transverse inclination, continuous max. (Option: max. operating inclina‐ L degree 22.5
tions)
TIM-ID: 0000002882 - 001
Transverse inclination, temporary max. (Option: max. operating inclinations) L degree 40
CAPACITIES
Engine oil capacity, initial filling (standard oil system) (Option: max. operat‐ R liter 73
ing inclinations)
Oil change quantity, max. (standard oil system) (Option: max. operating in‐ R liter 67
clinations)
44 | Technical Data | M015630/04E 2012-07

Oil pan capacity, dipstick mark min. (standard oil system) (Option: max. op‐ L liter 54
Oil pan capacity, dipstick mark max. (standard oil system) (Option: max. op‐ L liter 62
WEIGHTS / MAIN DIMENSIONS

Engine dry weight (with attached standard accessories, without coupling) R kg 1970
ACOUSTICS
Exhaust noise, unsilenced - FSP (free-field sound-pressure level Lp, 1m R db(A) 108
distance, ISO 6798)
Engine surface noise with attenuated intake noise (filter) - FSP (free-field R db(A) 104
sound pressure level Lp, 1m distance, ISO 6798)
TIM-ID: 0000002882 - 001

3.2 8V 2000 M72 engine data: Engine-mounted heat exchanger
Explanation:
A Design value
G Guaranteed value
R Guideline value
- Not applicable
X Applicable
Engine model 8V
2000
M72


Bore mm 135
TIM-ID: 0000002930 - 001
Stroke mm 156

RAW WATER CIRCUIT (open circuit)
Raw water pump: inlet pressure, min. L bar -0.4
Raw water pump: inlet pressure, max. L bar +0.5
Pressure loss in off-engine raw water system, max. L bar 1.2
LUBE-OIL SYSTEM
FUEL SYSTEM

STARTING (electric)

TIM-ID: 0000002930 - 001
ating inclinations)
tions)

CAPACITIES
Engine coolant capacity (with cooling equipment) R liter 100
ing inclinations)
clinations)

ACOUSTICS
distance, ISO 6798)
TIM-ID: 0000002930 - 001

3.3 10V 2000 M72 engine data: Separate heat exchanger
Explanation:
A Design value
G Guaranteed value
R Guideline value
- Not applicable
X Applicable
Engine model 10V
2000
M72


Bore mm 135
TIM-ID: 0000002964 - 001
Stroke mm 156

LUBE-OIL SYSTEM
FUEL SYSTEM

STARTING (electric)

ating inclinations)
tions)
TIM-ID: 0000002964 - 001
CAPACITIES
ing inclinations)
clinations)


ACOUSTICS
distance, ISO 6798)
TIM-ID: 0000002964 - 001

3.4 10V 2000 M72 engine data: Engine-mounted heat exchanger
Explanation:
A Design value
G Guaranteed value
R Guideline value
- Not applicable
X Applicable
Engine model 10V
2000
M72


Bore mm 135
TIM-ID: 0000002988 - 001
Stroke mm 156

RAW WATER CIRCUIT (open circuit)
Raw water pump: inlet pressure, min. L bar -0.4
Raw water pump: inlet pressure, max. L bar +0.5
Pressure loss in off-engine raw water system, max. L bar 1.2
LUBE-OIL SYSTEM
FUEL SYSTEM

STARTING (electric)

TIM-ID: 0000002988 - 001
ating inclinations)
tions)

CAPACITIES
Engine coolant capacity (with cooling equipment) R liter 114
ing inclinations)
clinations)

ACOUSTICS
distance, ISO 6798)
TIM-ID: 0000002988 - 001

3.5 Firing order
Firing order
8V A1-B4-A4-A2-B3-A3-B2-B1
10 V A1-B4-A4-B3-A3-B2-A2-B5-A5-B1
TIM-ID: 0000002801 - 004

3.6 Engine – Main dimensions
Main dimensions
Engine model Length (A) Width (B) Height (C)

8V 2000 M72 approx. 1683 mm approx. 1147 mm approx. 1200 mm
TIM-ID: 0000002153 - 003

4 Operation
4.1 Engine – Putting the engine into operation (out of service > 3
months)
Preconditions
☑ Engine is stopped and starting disabled.
☑ MTU Fluids and Lubricants Specifications (A001061/..) are available.
Putting the engine into operation (out-of-service period > 3 months)

Item Measure
Engine Depreserve (→ MTU Fluids and Lubricants Specifications A001061/..).
Lube oil system Check engine oil level (→ Page 113).
Fuel prefilter Fill with fuel (→ Page 106).
Align adjustable pointer with position of pressure indicator (→ Page 102).
Fuel system Vent (→ Page 99).
Raw water pump (if located Fill with water (approx. 3 – 4 liters).
above waterline)
Filling point (→ Page 120).
Coolant circuit If engine is out of service for more than one year, change engine coolant
(→ Page 126).
Check coolant level (→ Page 125).
Heat engine coolant with coolant preheating unit.
Engine control system Switch on (→ Operating Instructions for BlueVision).
Engine Start (→ Operating Instructions for BlueVision ).
TIM-ID: 0000002214 - 002
M015630/04E 2012-07 | Operation | 57

4.2 Putting the engine into operation after scheduled out-of-
service period
Preconditions
Startup
Item Task
Lube oil system Check oil level (→ Page 113).
Coolant system Check coolant level (→ Page 125).
Coolant system Preheat coolant with preheating unit.
Fuel prefilter Drain (→ Page 103).
Battery-charging generator Check condition of drive belt (→ Page 133).
drive
Engine control system Switch on (→ Operating instructions BlueVision ).
Engine Start (→ Operating instructions BlueVision ).
TIM-ID: 0000002690 - 001
58 | Operation | M015630/04E 2012-07

4.3 Tasks after extended out-of-service periods (>3 weeks)
Tasks after extended out-of-service periods (>3 weeks)

Note: Operate fuel treatment system for at least 5 minutes.
1. Start up fuel treatment system (→ Page 61).
2. Shut down fuel treatment system (→ Page 69).
TIM-ID: 0000007730 - 005
M015630/04E 2012-07 | Operation | 59

4.4 Checks prior to start-up
Checks prior to start-up

1. Check tank and the entire pipework for cleanness. If microorganisms are detected:
a) Clean affected components.
b) Disinfect affected components with biocides (→ MTU Fluids and Lubricants Specifications
A001061/..).
2. Close drain valves on housing.
3. Open all supply and discharge valves.
4. Switch on fuel treatment system (→ Page 64).
5. Check direction of rotation of pump.
6. Vent bypass and fuel lines of the system.
a) Open ball valve for pressure tank.
b) Open ball valve for overflow tank.
c) Close ball valve at the inlet to the fuel treatment system.
Result: Bypass line is vented via the overflow tank.
d) Open ball valve at the inlet to the fuel treatment system.
7. Check the fuel treatment system for leaks.
Result: The fuel treatment system is ready for operation.
TIM-ID: 0000007736 - 005
60 | Operation | M015630/04E 2012-07

4.5 Fuel treatment system – Putting into operation
Fuel treatment system – Overview

2. Check the differential pressure at differential pressure gauge (8). Differential pressure in a new system:
0.1 bar to 0.3 bar.
Result: If no differential pressure is measured, the coalescer filter element is probably being bypassed.
1. Remove coalescer filter element (→ Page 141).
2. Check sealing faces on coalescer filter element and in the pressure tank.
Initial operation: HAT

1. Replace fuel filter on engine (→ Page 100).
Note: Determine the suction pressure upstream of the engine-mounted fuel delivery pump.
2. Install a pressure gauge in the fuel supply line from the shipyard-side fuel system to the engine.
3. Switch on fuel treatment system and operate it for some minutes (→ Page 64).
Result: Fuel is sucked from the tank, dirt particles and water are filtered and separated, then the fuel is delivered
via the overflow tank back to the tank. Water which has settled in the tank is separated.
TIM-ID: 0000007738 - 005
4. Start engine (→ Page 63).

5. Run engine at idling speed.
6. Check suction pressure (see technical data of the engine) at the engine-mounted fuel delivery pump.
Note: If the suction pressure is within the permissible limits and engine operation is satisfactory:
7. Increase engine speed to 1000 rpm and monitor suction pressure.
8. Check suction pressure at the engine-mounted fuel delivery pump.
Result: If the values are within the limits specified by the manufacturer, the system is ready to start filter replace‐
ment simulation with the engine running as part of the Harbor Acceptance Tests.
M015630/04E 2012-07 | Operation | 61

Simulation of filter replacement with the engine running: HAT
4. Close ball cock (5) at the inlet to the fuel treatment system.
Result: The pressure upstream of the fuel treatment system increases until the overflow valve at the pump unit
opens and fuel flows through bypass (3) and bypass (2).
5. Open ball cock (19).
Result: Fuel emerges. If no fuel emerges:
• Open ball cock (5) at the inlet to the fuel treatment system.
• No function of bypasses (2) and (3); carry out functional test of bypasses (2) and (3).
6. Check suction pressure (see technical data of the engine) at the fuel delivery pump.
Result: If all engine operating values are within the specified limits, open ball cock (5) at the inlet to the fuel treat‐
ment4 system.
Simulation of power failure (emergency): HAT

4. Switch off pump (21) on switch cabinet.
Result: The engine-mounted fuel delivery pump sucks fuel via bypass (2) directly from the tank.
Note: If the suction pressure is within the permissible limits and engine operation is satisfactory.
Result: If the suction pressure is within the specified limits, simulation was successful.
Simulation of power failure (emergency): SAT

4. Switch off pump (21) on switch cabinet.
Result: The engine-mounted fuel delivery pump sucks fuel via bypass (2) directly from the tank.
6. Operate engine at full load and monitor suction pressure.
Result: If the suction pressure is within the specified limits, simulation was successful.
TIM-ID: 0000007738 - 005
62 | Operation | M015630/04E 2012-07

4.6 Starting the engine
Preconditions
☑ External start interlock is not active.
☑ Emergency air shut-off flaps (if fitted) are open.
DANGER
Unguarded rotating and moving engine components.
Risk of serious injury – danger to life!
• Before barring or starting the engine, make sure that nobody is in the danger zone.
WARNING
Engine noise above 85 dB (A).
Risk of damage to hearing!
The engine can be started from the following points

Item Action
Control stand (→ Operating instructions for electronic system)
Local Operating Panel LOP (→ Operating instructions for electronic system)
Local Operation Station (→ Operating instructions for electronic system)
LOS
CCU (→ Operating instructions for electronic system)
TIM-ID: 0000002240 - 003
M015630/04E 2012-07 | Operation | 63

4.7 Fuel treatment system – Switching on
Preconditions
☑ The on-board power supply is switched on.
CAUTION
Damage to engine/plant.
Major material damage!
• Before switching on, ensure that the engine/plant is ready for operation.
• Before switching on, ensure that all housings are closed.
• Before switching on, ensure that no work is in progress anywhere on the entire system.
Switching on fuel treatment system

1. Carry out checks prior to start-up (→ Page 60).
2. Switch on master switch on switch cabinet.
Result: Signal lamp “Control voltage present” lights up.
3. Switch on switch for pump.
Result: Signal lamp “Pump running” lights up.
TIM-ID: 0000007731 - 005
64 | Operation | M015630/04E 2012-07

4.8 Operational checks
DANGER
• Take special care when working on a running engine.
WARNING
Operational checks
Item Measure
Engine under load Visually inspect engine for leaks and general condition;
Engine at nominal speed Check for abnormal running noises and vibration;
Check exhaust color (→ Page 73).
Fuel prefilter Check fuel prefilter contamination indicator for max. admissible value
(→ Page 102).
Drain water and contaminants (→ Page 103).
Air filter Check signal ring position of contamination indicator (→ Page 111).
HT coolant pump Check relief bore for oil and coolant discharge and contamination
(→ Page 129).
Raw water pump Check relief bore for oil and water discharge and contamination
(→ Page 132).
Intercooler Check condensate drain (if applicable) (→ Page 108).
Engine oil Check engine oil level (→ Page 113).
TIM-ID: 0000002274 - 005
M015630/04E 2012-07 | Operation | 65

4.9 Stopping the engine
Preconditions
☑ Engine is running in local mode.
CAUTION
Stopping the engine when it is running at full load causes extreme stress to the engine.
Risk of overheating, damage to components!
• Before shutting down, disengage gear and run the engine at idle speed for at least 10 mins. until
engine temperatures have dropped and constant values are displayed.
The engine can be stopped from the following points :

1. (→ Operating instructions for electronic system)
2. Commanding control stand (→ Operating instructions for electronic system);
3. Local operating panel LOP (→ Operating instructions for electronic system);
4. Local Operation Station LOS (→ Operating instructions for electronic system);
5. CCU (→ Operating instructions for electronic system).
TIM-ID: 0000002298 - 002
66 | Operation | M015630/04E 2012-07

4.10 Emergency stop
CAUTION
An emergency stop causes extreme stress to the engine.
Risk of overheating, damage to components!
• Initiate emergency stop only in emergency situations.
An emergency stop of the engine can be initiated from the following points :
1. (→ Operating instructions for electronic system)
2. Commanding control stand (→ Operating instructions for electronic system);
3. Local operating panel LOP (→ Operating instructions for electronic system);
4. Local Operation Station LOS (→ Operating instructions for electronic system);
5. CCU (→ Operating instructions for electronic system).
TIM-ID: 0000002312 - 002
M015630/04E 2012-07 | Operation | 67

4.11 After stopping the engine
Preconditions
After stopping the engine

Item Action
Coolant circuit Drain coolant (→ Page 127) if:
• freezing temperatures are expected and the engine is to remain out of
service for an extended period, but engine coolant has no antifreeze
additive;
• the engine room is not heated;
• the coolant is not kept at a suitable temperature;
• the antifreeze concentration is insufficient for the engine-room tempera‐
ture;
• antifreeze concentration is 50 % and engine-room temperature is below
-40 °C.
Raw water Drain
• If freezing temperatures are to be expected and the engine is to remain
out of service for an extended period.
Engine control system Switch off.
Air intake and exhaust sys‐ Out-of-service-period > 1 week
tem • Seal engine's air and exhaust sides.
Engine Out-of-service-period > 1 month
• Preserve engine (→ MTU Fluids and Lubricants Specifications
A001061/.. )
TIM-ID: 0000002324 - 007
68 | Operation | M015630/04E 2012-07

4.12 Fuel treatment system – Shutdown
Shutting down fuel treatment system

1. Press the illuminated pushbutton "Water drain" on the switch cabinet until water discharge from the outlet
stops.
2. Switch off fuel treatment system.
3. Close ball valve at the inlet to the fuel treatment system.
4. Close ball valve at the outlet of the fuel treatment system.
5. Open drain valve until pressure has escaped from fuel treatment system.
TIM-ID: 0000007732 - 005
M015630/04E 2012-07 | Operation | 69

4.13 Plant cleaning
Preconditions
☑ Operating voltage is not present.
Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Steam jet cleaner - 1
Cleaner (Hakupur 312) 30390 1
WARNING
Compressed air
Risk of injury!
• Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.
WARNING
Water jet.
Risk of injury and scalding!
• Do not direct water jet at persons.
• Wear protective clothing, gloves, and goggles / safety mask.
CAUTION
Excessive reaction time of cleaning agents on components.
Damage to component!
• Observe manufacturer's instructions.
NOTICE
Dry with compressed air.
• Never aim compressed air directly at electronic components.
Plant cleaning
1. Carry out plant cleaning only in areas where an appropriate oil separator is provided (environmental pro‐
tection).
2. Prior to putting the cleaning unit into operation, read the Operating Instructions of the water/steam jet unit
carefully and observe the safety precautions.
3. During external cleaning of the plant with water/steam-jet units, the pressure of the high-pressure jet
(cleaning jet) must not exceed 50 bar. A minimum distance between spray nozzle and plant of 1 m must
be observed. The temperature of the cleaning medium must not exceed 80 °C.
TIM-ID: 0000010171 - 024
4. For external cleaning with high-pressure jet, use a flat-mouth nozzle only.
5. Carry out external cleaning as follows:
a) Seal all openings in a suitable fashion.
b) Remove coarse dirt.
c) Spray on cleaner sparingly and leave it for 1 to 5 minutes.
d) Use the high-pressure jet to remove the loosened dirt.
Note: Never aim compressed air directly at electronic components.
e) Dry engine.
70 | Operation | M015630/04E 2012-07

5 Maintenance
5.1 Maintenance task reference table [QL1]
The maintenance tasks and intervals for this product are defined in the Maintenance Schedule. The
Maintenance Schedule is a stand-alone publication.
The task numbers in this table provide reference to the maintenance tasks specified in the Maintenance
Schedule.
Task
W0500 (→ Page 113)
W0501 Visual inspection
W0502 (→ Page 108)
W0503 (→ Page 111)
W0505 (→ Page 129)
W0506 (→ Page 73)
W0507 (→ Page 103)
W0508 (→ Page 102)
W1001 (→ Page 100)
W1002 (→ Page 92)
W1003 (→ Page 133)
W1005 (→ Page 109)
W1006 (→ Page 96)
W1008 (→ Page 115)
W1009 (→ Page 117)
W1011 (→ Page 85)
W1036 (→ Page 131)
W1139 (→ Page 90)
W1140 (→ Page 89)
W1244 (→ Page 139)
W1245 (→ Page 138)
W1246 (→ Page 140)
Table 1: Maintenance task reference table [QL1]
TIM-ID: 0000023885 - 003
M015630/04E 2012-07 | Maintenance | 71

6 Troubleshooting
6.1 Fuel treatment system – Troubleshooting
Illuminated pushbutton “Water alarm” is lit.

Cause Corrective action
When the maximum water level 1. Press illuminated pushbutton “Water alarm” to acknowledge.
is reached, the water level elec‐ 2. In addition to the automatic water drain function, water can also
trode opens the water drain be drained manually. To do so, press the illuminated pushbutton
valve and water is discharged. If “Water drain” to open the drain valve.
the opening period of the valve
exceeds a preset limit (4 mi‐
nutes), the pump will switch off
and an alarm is initiated.
Signal lamp “Pump fault” is lit.

The drive motor is equipped with u Reset motor protection relay.
an overload protection. If the
maximum permissible current
consumption is exceeded, e.g. in
case of a blockage or dry-run‐
ning, the motor protection relay
triggers and the pump is switch‐
ed off.
Signal lamp “Warning filter” is lit.

The differential pressure exceed‐ u Replace coalescer filter element (→ Page 141).
ed 1.3 bar.
Illuminated pushbutton “Replace filter element” is lit.

The max. permissible differential 1. Replace coalescer filter element (→ Page 141).
pressure of 1.5 bar was exceed‐ 2. Press illuminated pushbutton “Replace filter element” to ac‐
ed. If the coalescer filter element knowledge.
is not replaced, pressure will in‐
crease further and the safety
TIM-ID: 0000007734 - 006
valve will open. Fuel will be led

via the bypass directly into the
overflow tank.
72 | Troubleshooting | M015630/04E 2012-07

6.2 Troubleshooting
Engine does not turn when starter is actuated

Component Cause Action
Battery Low or faulty Charge or replace (see manufacturer's
documentation).
Cable connections faulty Check if cable connections are proper‐
ly secured (see manufacturer's docu‐
mentation).
Starter Engine wiring or starter faulty Check if cable connections are proper‐
ly secured, contact Service.
Engine cabling Faulty Check (→ Page 143).
ECU Plug-in connections possibly loose Check plug connections for secure
seating.
Engine Running gear blocked (engine cannot Contact Service.
be barred manually)
Engine turns but does not fire

Starter Poor rotation by starter:Battery low or Charge or replace battery (see manu‐
faulty facturer's documentation).
Fuel system Air in fuel system Vent fuel system (→ Page 99)
ECU Faulty Contact Service.
Engine fires unevenly

Fuel injection equip‐ Injector faulty Replace (→ Page 96).
ment
Engine does not reach rated speed

Fuel supply Fuel prefilter clogged Replace (→ Page 106).
TIM-ID: 0000002555 - 003
Fuel filter clogged Replace (→ Page 100).

Air supply Air filter clogged Check signal ring position of service in‐
dicator (→ Page 111).
ment
Engine Overloaded Contact Service.
M015630/04E 2012-07 | Troubleshooting | 73

Engine speed not steady
ment
Speed sensor Faulty Replace.
Charge air temperature too high

Engine coolant Engine coolant treatment incorrect Check.
Intercooler Contaminated Contact Service.
Engine room Air-intake temperature too high Check fans and air supply / ventilation
ducts.
Charge-air pressure too low

Intercooler Contaminated Contact Service.
Exhaust turbocharger Faulty Contact Service.
Coolant leaks at intercooler

Intercooler Leaking, major coolant discharge Contact Service.
Black exhaust gas

ment
Engine Overloaded Contact Service.
Blue exhaust gas

TIM-ID: 0000002555 - 003
Engine oil Too much oil in engine Drain engine oil (→ Page 114).
Oil separator or oil-preseparator of • Clean preseparator (→ Page 89);
crankcase breather clogged • Replace oil separator element
(→ Page 90).
Exhaust turbocharg‐ Faulty Contact Service.
er, cylinder head, pis‐
ton rings, cylinder lin‐
er
74 | Troubleshooting | M015630/04E 2012-07

White exhaust gas
Engine Not at operating temperature Run engine to reach operating temper‐
ature.
Fuel system Water in fuel Drain fuel prefilter (→ Page 103).
Intercooler Leaking Contact Service.
TIM-ID: 0000002555 - 003
M015630/04E 2012-07 | Troubleshooting | 75

7 Task Description
7.1 SOLAS
7.1.1 Installation locations for SOLAS shielding
General information
Primarily fit SOLAS shielding as per MTN 5233 (→ Page 82).
On crankcase
Item Type of shielding Remarks

1 Shield (A4) On brazed-on union
2 Shield (A5) On crankcase
TIM-ID: 0000010065 - 006
76 | Task Description | M015630/04E 2012-07

Free end B-side

1 Shield (A7) On fuel delivery pump
Free end
B-side
Free end B-side

TIM-ID: 0000010065 - 006

1 Shield (A7) On HP fuel pump
Free end
B-side
M015630/04E 2012-07 | Task Description | 77

Free end

1 Shield (A7) Above fuel priming pump
Free end
Free end
TIM-ID: 0000010065 - 006

1 Shield (A7) Below fuel priming pump
Free end

Free end

1 Shield (A8) On fuel filter housing
Free end
Driving end A-side

TIM-ID: 0000010065 - 006

1 Shield (A5) On valve plate
Driving end

Driving end A-side

1 Shield (A5) On air flap control
Driving
end
Driving
end
3 Shield (A5) On exhaust turbocharger flap control
Driving
end
4 Shield (A5) On exhaust turbocharger flap control
Driving
end
TIM-ID: 0000010065 - 006

Driving end

1 Shield (A4) Exhaust turbocharger lubrication
Driving
end
Driving
end
Driving end
TIM-ID: 0000010065 - 006

1 Shield (A4) Exhaust turbocharger lubrication
Driving
end

7.1.2 SOLAS shielding – Installation as per MTN 5233
Preconditions

Shield A4 735233000100 5
Shield A5 735233000101 7
Shield A7 735233000103 6
Shield A8 735233000104 2
Installing SOLAS shielding

1. Pinpoint installation location (→ Page 76).
2. Install suitable shielding.
3. Press shielding until locked.
TIM-ID: 0000010551 - 004

7.2 Engine
7.2.1 Engine – Barring manually
Preconditions

Barring tool F6783914 1
Ratchet F30006212 1
DANGER
• Before barring or starting the engine, ensure that nobody is in the danger zone.
• After working on the engine, check that all protective devices have been reinstalled and all tools
removed from the engine.
Engine – Barring manually

1. Fit ratchet with barring tool on barring tool connection at the vibration damper on engine free end.
2. Rotate crankshaft in engine direction of rotation. Apart from the normal compression resistance, there
should be no resistance.
Result: If the resistance exceeds the normal compression resistance, contact Service.
TIM-ID: 0000002527 - 002

7.2.2 Engine – Barring with starting system
Preconditions
☑ Clutch is disengaged.
☑ Engine start is disabled.
☑ LOP is accessible and open.
DANGER
• Before barring or starting the engine, ensure that nobody is in the danger zone.
• After working on the engine, check that all protective devices have been reinstalled and all tools
removed from the engine.
Barring
1. Press barring button on the LMB mother‐
board of the LOP and keep it depressed.
Result: Engine is barred by starter for max. 20 sec‐
onds.
2. Release barring button.
TIM-ID: 0000002788 - 001

7.3 Cylinder Liner
7.3.1 Cylinder liner – Endoscopic examination
Preconditions
☑ Engine is stopped and starting disabled

Rigid endoscope Y20097353 1
Preparatory steps
1. Remove cylinder head cover (→ Page 95).
2. Remove injector (→ Page 97).
Positioning crankshaft at BDC

1. Using barring gear, turn crankshaft until crankshaft journal of the cylinder to be inspected has reached
BDC.
2. Insert endoscope into cylinder liner through injector seat.
Endoscopic examination of cylinder liner

Findings Action
• Thin carbon coating on circumference of carbon scraper ring No action required
• Slight localized additive deposits at top edge
• Localized smooth areas on bottom edge
• Carbon deposits on circumference in clearance between top piston
ring and bottom edge of carbon scraper ring
• First signs of marks left by top piston ring
• Bright mark on entire circumference
• Consistent honing pattern without objections
• First signs of marks left by lower cooling bores
• Running pattern seems darker
• Dark areas with even or varying degrees of discoloration Further endoscopic examina‐
• Beginning and end of the discoloration are not sharply defined and tion required as part of main‐
do not cover the entire stroke area tenance work
• Dark areas in the upper section of the cooling bore, remaining cir‐
cumference without objections
• Piston rings without objections
• On the entire circumference, apart from light areas of discoloration Cylinder liner must be re‐
(that do not impair operation) clearly darker stripes that start at the placed; Service must be con‐
TIM-ID: 0000000015 - 013
top piston ring tacted

• Heat discoloration in the direction of stroke and honing pattern dam‐
age
• Heat discoloration of piston rings
1. Compile endoscopy report using the table.
2. Use technical terms for description of the liner surface (→ Page 87).
3. Depending on findings:
• do not take any action or
• carry out a further endoscopic examination as part of maintenance work or
• contact Service; cylinder liner must be replaced.

Final steps
1. Install injector (→ Page 97).
2. Install cylinder head cover (→ Page 95).
TIM-ID: 0000000015 - 013

7.3.2 Cylinder liner – Instructions and comments on endoscopic and visual
examination
Terms used for endoscopic examination

Use the terms listed below to describe the condition of the cylinder-liner surface in the endoscopic exami‐
nation report.
Findings Measure
Minor dirt scores Minor dirt scores can occur during the assembly of a new engine (honing prod‐
ucts, particles, broken-off burrs). Removed cylinders clearly show such scoring
on the running surface under endoscope magnification. Cannot be felt with the
fingernail.
Findings not critical.
Single scores Clearly visible scores caused by hard particles. They usually start in the TDC
area and cross through the hone pattern in the direction of stroke.
Scored area These areas consist of scores of different length and depth next to one anoth‐
er. In most cases, they are found at the 6-o'clock and 12-o'clock positions (in‐
let/exhaust) along the transverse engine axis.
Smoothened area Smoothened areas are on the running surface but almost the whole honing
pattern is still visible. Smoothened areas appear brighter and more brilliant
than the surrounding running surface.
Bright area Bright areas are on the running surface and show local removal of the honing
pattern. Grooves from honing process are not visible any more.
Discoloration This is caused by oxidation (surface discoloration through oil or fuel) and tem‐
perature differences around the liner. It appears rather darker within the honed
structure in contrast to the bright metallic running surface. The honing pattern
is undisturbed. Discolorations extend in stroke direction and may be interrupt‐
ed.
Corrosion fields / spots Corrosion fields / spots result from water (condensed water) with the valves in
the overlap (open) position. They are clearly visible due to the dark color of the
honing groove bottom.
This corrosion is not critical unless there is corrosion pitting.
Black lines Black lines are a step towards heat discoloration. They are visible as a clear
discoloration from TDC to BDC in the running surface and the start of localized
damage to the honing pattern.
TIM-ID: 0000000014 - 013
Cylinder liners with a large number of black lines around the running surface
have limited service life and should be replaced.

Findings Measure
Burn mark This is caused by a malfunction in the liner / ring tribosystem. Usually they run
over the whole ring-travel area (TDC/BDC), starting at the first TDC-ring and
becoming more visible from the second TDC-ring 2 onwards and less pro‐
nounced from TDC-ring 1. The honing pattern is usually no longer visible and
displays a clearly defined (straight) edge to the undisturbed surface. The dam‐
aged surface is usually discolored. The circumferential length varies.
Liners with burn marks, or heat discoloration, starting in TDC ring 1 have to be
replaced.
Seizure marks, scuff‐ Irregular circumference lengths and depths. Can be caused either by the pis‐
ing ton skirt or the piston crown. Material deposits on the liner (smear), heavy dis‐
coloration. Severe, visible scoring.
Replace liner.
Evaluation of findings and further measures

The findings in the start phase of oxidation discoloration and heat discoloration are similar. A thorough
investigation and compliance with the above evaluation criteria allow an unambiguous evaluation. To
avoid unnecessary disassembly work, it is recommended that another inspection be carried out after fur‐
ther operation of the engine.
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7.4 Crankcase Breather
7.4.1 Crankcase breather – Cleaning oil pre-separator element
Preconditions

fuel
WARNING
Fuels are combustible.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
WARNING
Compressed air
Risk of injury!
Crankcase breather – Cleaning oil

pre-separator element
1. Remove cover (1) from housing (4).
2. Remove oil separator (2) and gasket (3).
3. Clean oil separator (2) in fuel and blow dry
with compressed air.
4. Moisten oil separator (2) with engine oil.
5. Place oil separator (2) with new gasket (3)
onto housing (4) and install cover (1).
6. Clean further oil pre-separator element in
the same way.
TIM-ID: 0000003470 - 002

7.4.2 Crankcase breather – Oil separator element replacement, diaphragm check
and replacement
Preconditions

Torque wrench, 6-50 Nm F30027336 1
Ratchet F30027340 1
Engine oil
Filter element (→ Spare Parts Catalog)
Diaphragm (→ Spare Parts Catalog)
Gasket (→ Spare Parts Catalog)
WARNING
Hot oil.
Oil can contain combustion residues which are harmful to health.
Risk of injury and poisoning!
• Avoid contact with skin.
• Do not inhale oil vapor.
Replacing oil separator element

1. Remove cover (2) with O-ring (3).
2. Remove filter element (1) from housing (4).
3. Insert new filter element in housing (4).
4. Install cover (2) with new O-ring.
TIM-ID: 0000000017 - 007
5. Use torque wrench to tighten the screws of cover (2) to the specified torque.
Name Size Type Lubricant Value/Standard
Screw Tightening torque (Engine oil) 10 Nm − 2 Nm
6. Replace further oil separator elements in the same way.

Checking diaphragm
1. Remove cover (4).
2. Remove spring (5), gasket (2) and dia‐
phragm (3).
3. Check diaphragm (3) for damage, fit new
diaphragm if used one is damaged.
4. Install diaphragm (3) on housing (1).
5. Install new seal (2) and spring (5) together
with cover (4).
6. Use torque wrench to tighten the screws of cover (4) to the specified torque.
Screw Tightening torque (Engine oil) 10 Nm − 2 Nm
7. Check diaphragms in further oil separators in the same way.
TIM-ID: 0000000017 - 007

7.5 Valve Drive
7.5.1 Valve clearance – Check and adjustment
Preconditions
☑ Engine coolant temperature is max. 40 °C.
☑ Valves are closed.

Feeler gauge Y4345893 1
Barring tool F6783914 1
Ratchet F30006212 1
Double box wrench F30002800 1
Angular screw driver F30002816 1
Socket wrench F30030450 1
Measuring device Y4345888 1
Preparatory steps
1. Remove air filter (→ Page 110).
Positioning A1 piston at TDC

Note: With cylinder head and valve gear installed.
1. Install dial gauge (2) under preload in
measuring device (4) and clamp with
screw (1).
2. Install measuring device (4) in cylinder
head and secure using knurled screw (3).
3. Zero dial gauge (2).
4. Turn engine using barring tool until piston
A1 reaches firing TDC.
Result: The piston is at firing TDC when both rock‐
er arms are unloaded, i.e. have clearance.
TIM-ID: 0000004363 - 004

Checking valve clearance at two crankshaft positions
1. Check TDC position of piston in cylinder A1:
• If the rocker arms are unloaded on cylinder A1, the piston is in firing TDC.
• If the rocker arms are loaded on cylinder A1, the piston is in overlap TDC.
2. Check valve clearance with cold engine:
• Inlet (E) = 0.3 mm;
• Exhaust (A) = 0.4 mm.
3. Check all valve clearances at two crankshaft positions (firing TDC and overlap TDC) according to the
table below.
8V2000
Position Cylinder 1 2 3 4 5 6 7 8 9
Firing TDC in cylinder A1 Bank A EA -A E- -A
Bank B E- E- -- -A
Overlap TDC in cylinder A1 Bank A -- E- -A E-
Bank B -A -A EA E-
“E” = inlet valve clearance adjustment permitted, “A” = exhaust valve clearance adjustment permitted
10V2000
Firing TDC in cylinder A1 Bank A EA -- -- -A E-
Bank B E- -- -A EA E-
Overlap TDC in cylinder A1 Bank A -- EA EA E- -A
Bank B -A EA E- -- -A
12V2000
Firing TDC in cylinder A1 Bank A EA E- -A E- -A --
Bank B E- -- -A E- E -A
A
Overlap TDC in cylinder A1 Bank A -- -A E- -A E- EA
Bank B -A EA E- -A -- E-
16V2000
Firing TDC in cylinder A1 Bank A E A - A - A E - -A E - - - - -
Bank B E - - A - - E - E E - E - A
A A
TIM-ID: 0000004363 - 004
Overlap TDC in cylinder A1 Bank A - - E - E - - A E - -A E EA

A
Bank B -A E - E A - A - - -A -- E-
18V2000

Firing TDC in cylinder A1 Bank A E A E- - A E - -A - - -A - - --
Bank B -A - A - - E A -- E E- EA E-
A
Overlap TDC in cylinder A1 Bank A - - - A E - - A E - EA E- EA E A
Bank B E- E - E A - - E -- -A -- -A
A
4. Use feeler gauge to determine the distance between valve bridge and rocker arm.
5. If the deviation from the reference value exceeds 0.1 mm, adjust valve clearance.
Valve clearance adjustment

1. Loosen locknut (1) and unscrew adjusting
screw (2) by a few threads.
2. Insert feeler gauge between valve bridge
and rocker arm.
3. Readjust adjusting screw (2) so that the
feeler gauge just passes through the gap.
4. Tighten locknut (1) with torque wrench to
the prescribed tightening torque of 50 Nm
while holding the adjusting screw (2) with
Allen key.
5. Insert feeler gauge between valve bridge
and rocker arm to verify that the gauge just
passes through the gap.
Result: If not, adjust valve clearance.
Final steps
1. Remove barring tool.
3. Install air filter (→ Page 110).
TIM-ID: 0000004363 - 004

7.5.2 Cylinder-head cover – Removal and installation
Preconditions

Centering device F6783025 1
Preparatory steps
1. Remove air filter (→ Page 110).
2. Remove intake housing.
Cylinder-head cover – Removal

and installation
1. Remove screws (1).
2. Remove cylinder-head cover (2) with gas‐
ket from cylinder head.
3. Clean mating faces.
4. Check condition of gasket of cylinder-head
cover.
Result: Replace damaged gasket(s).
5. Center cylinder-head cover (2) with center‐
ing device.
6. Use torque wrench to tighten screws (1) to
specified torque 20 Nm.
Final steps
1. Install air filter (→ Page 110).
2. Install intake housing.
3. Check cylinder-head covers for leaks.
TIM-ID: 0000004470 - 001

7.6 Injection Valve / Injector
7.6.1 Injector – Replacement

Injector (→ Spare Parts Catalog)
Remove injector and install new one.

u (→ Page 97)
TIM-ID: 0000004642 - 002

7.6.2 Injector – Removal and installation
Preconditions

Socket wrench 0005896803/00 1
Puller F6790629 1
Double box wrench F30011450 1
Open end wrench bit F30025897 1
Box wrench adapter F30451199 1
Alignment device F6790507 1
Grease (Kluthe Hakuform 30-10/Emulgier) X00029933 1
Engine oil
WARNING
• Do not smoke.
Preparatory steps
1. Close fuel supply to engine.
Removing injector
1. Remove HP line (5) using socket wrench.
2. Disconnect injector cable (4).
3. Remove screw (2).
4. Take off hold-down clamp (3).
5. Remove injector (1) with puller.
6. Remove O-rings from injector.
7. Mask all connections and bores or seal with
suitable plugs.
TIM-ID: 0000004650 - 002

Installing injector
1. Remove all plugs before installation.
2. Fit new O-rings onto injector and coat with grease.
3. Fit new sealing ring with grease on injector, ensuring correct installation position of sealing ring.
4. Clean sealing surface on cylinder head and protective sleeve.
5. Insert injector (1) in cylinder head, ensuring that it is correctly aligned with the HP line connection.
6. Fit hold-down clamp (3) in correct installation position, coat screw (2) with engine oil.
7. Screw in screw (2) and tighten by hand.
8. Coat thread and sealing cone of HP line (5) and injector (1) with engine oil.
9. Align injector (1) and HP line (5) with alignment device.
10. Connect HP line (5) to HP accumulator and tighten by hand.
11. Connect HP line (5) to injector (1) and tighten by hand.
12. Tighten screw of hold-down clamp (3) with a box wrench adapter and a torque wrench to specified tight‐
ening torque.
Screw M10 x 85 Tightening torque (Engine oil) 40 Nm + 4 Nm
13. Use socket wrench and torque wrench to tighten HP line (5) to the specified torque.
HP fuel line Tightening torque (Engine oil) 30 Nm + 5 Nm
14. Attach cable (4).
Final steps
2. Open fuel supply to engine.
TIM-ID: 0000004650 - 002

7.7 Fuel System
7.7.1 Fuel system – Venting
Preconditions
WARNING
• Do not smoke.
Venting fuel system

1. Unlock fuel priming pump, unscrew handle.
2. Open vent plugs on filter head.

Note: New version has two threaded vent plugs,
old version has four threaded vent plugs.
3. Operate the pump with the handle until fuel
without bubbles comes out of the vent plugs
and the nipples.
4. Close vent plugs on filter head.
5. Operate the pump with the handle until fuel
without bubbles comes out of the nipple.
6. Lock fuel priming pump, screw in handle.
TIM-ID: 0000004716 - 002

7.8 Fuel Filter
7.8.1 Fuel filter – Replacement

Oil filter wrench F30379104 1
Diesel fuel
Easy-change filter (→ Spare Parts Catalog)
DANGER
DANGER
WARNING
• Do not smoke.
WARNING
CAUTION
Damage to component.
Serious damage to plant!
• For filter replacement with the engine running, operate the engine at low engine load.
• The filter which is to be exchanged must be cut out for a brief period only.
TIM-ID: 0000004914 - 004

Easy-change fuel filter replacement
with the engine stopped
1. Stop engine and disable engine start.
2. Cut out the filter to be replaced.
B Left filter cut out
C Right filter cut out
3. Remove cut-out easy-change filter using
the oil filter wrench.
4. Clean sealing surface on filter head.
5. Check sealing ring of the new easy-change
filter and coat it with fuel.
6. Fit SOLAS shield (→ Page 82).
7. Screw on easy-change filter and tighten by
hand.
8. Set three-way cock to operating position (A)
so that both filters are cut in (operating po‐
sition).
9. Replace further fuel filters in the same way.
10. Vent fuel system (→ Page 99).
Easy-change fuel filter replacement

with the engine running
2. Open the threaded vent plugs at the filter
head of the cut-out filter and make sure that
the fuel filter is not pressurized.
Note: New version has two threaded vent plugs,
old version has four threaded vent plugs.
3. Close threaded vent plugs.
4. Remove cut-out easy-change filter using
the oil filter wrench.
5. Clean sealing surface on filter head.
6. Check sealing ring of the new easy-change
filter and coat it with fuel.
8. Screw on easy-change filter and tighten by
hand.
9. Set three-way cock to operating position
(both filters cut in).
10. Replace further fuel filters in the same way.
TIM-ID: 0000004914 - 004

7.8.2 Fuel prefilter – Differential pressure check and adjustment of gauge
DANGER
WARNING
Differential pressure gauge

adjustment
1. When installing the new filter element: align
adjustable pointer (2) with pressure-indicat‐
ing pointer (3) of pressure gauge (1).
2. Verify that differential pressure is within the
limit.
Fuel prefilter – Checking differential pressure

1. With the engine running at full load or rated power, read off pressure at gauge (1).
2. If differential pressure as indicated between position of adjustable pointer (2) and pressure indicator of
pressure gauge (3) is ≥ 0.3 bar, flush filter element of the cut-in filter (→ Page 104). TIM-ID: 0000004926 - 003

7.8.3 Fuel prefilter – Draining
Preconditions

Diesel fuel
Seal (→ Spare Parts Catalog)
WARNING
• Do not smoke.
Fuel prefilter – Draining

1. Cut out the filter to be drained.
I Left filter cut in
II Right filter cut in
2. Open threaded vent plug (5) of the filter to

be drained.
3. Unlock drain valve (6) by pressing toggle
and open it.
4. Drain water and contaminants from the filter
until pure fuel emerges.
5. Close drain valve (6).
6. Remove screws securing the cover and
take off cover (2).
TIM-ID: 0000004933 - 004
7. Fill filter housing with clean fuel.

8. Place new seal in cover (2).
9. Fit cover with gasket and secure it with
screws.
10. Cut in the cut-out filter again.
11. Close threaded vent plug (5) when fuel
emerges from system.

7.8.4 Fuel prefilter – Flushing

Diesel fuel
DANGER
WARNING
• Do not smoke.
WARNING
Fuel prefilter – Flushing

1. Switch off contaminated filter.
TIM-ID: 0000004939 - 002

2. Open threaded vent plug (5) of the filter to
be flushed.
3. Unlock drain valve (6) by pressing toggle,
open it and drain fuel.
Result: Fuel flows from filtered side back to the un‐
filtered side, flushing the filter deposits
downwards out of the filter.
4. Close threaded vent plug (5) and drain
valve (6).
Fuel prefilter – Filling with fuel

1. Stop engine (→ Operating Instructions for electronic system ) and disable engine start.
2. Remove screws securing the cover and take off cover (2).
5. Fit cover with gasket and secure it with screws.
6. Check differential pressure (→ Page 102).
Result: If flushing did not improve differential pressure, fit new filter element in fuel prefilter (→ Page 106).
TIM-ID: 0000004939 - 002

7.8.5 Fuel prefilter – Filter element replacement
Preconditions

Diesel fuel
Filter element (→ Spare Parts Catalog)
WARNING
• Do not smoke.
Replacing filter element

1. Cut out the contaminated filter.
TIM-ID: 0000004946 - 004

2. Open threaded vent plug (5) of contaminat‐
ed filter.
3. Unlock drain valve (6) by pressing toggle
and open it.
4. Drain water and contaminants from the fil‐
ter.
5. Close drain valve (6).
6. Remove screws securing the cover and
take off cover (2).
7. Remove spring housing (4) and filter ele‐
ment (3).
8. Insert new filter element (3) and spring
housing (4).
11. Fit cover with gasket and secure it with
screws.
12. Cut in the cut-out filter again.
13. Close threaded vent plug (5) when fuel
emerges.
14. Set adjustable pointer of differential pres‐
sure gauge (→ Page 102).
TIM-ID: 0000004946 - 004

7.9 Charge-Air Cooling
7.9.1 Intercooler – Checking condensate drain line for coolant discharge and
obstruction
DANGER
WARNING
WARNING
Compressed air
Risk of injury!
Intercooler – Checking condensate

drain line for coolant discharge and
obstruction
1. Check drain line for water discharge and
obstruction when the engine is running idle.
2. If no air emerges, remove condensate drain
line and blow out with compressed air.
3. Replace obstructed drain line by new one.
4. Install condensate drain line.
5. If a large amount of coolant is continuously
discharged, the intercooler is leaking. Con‐
tact Service.
Emergency measures prior to engine start with a leaking intercooler

1. Remove injectors (→ Page 96).
TIM-ID: 0000027574 - 003
2. Bar engine manually (→ Page 83).

3. Bar engine with starting system to blow out combustion chambers (→ Page 84).
4. Install injectors (→ Page 97).

7.10 Air Filter
7.10.1 Air filter – Replacement

Air filter (→ Spare Parts Catalog)
Replacing the air filter

1. Remove old air filter and install new air filter (→ Page 110).
2. Reset signal ring of contamination indicator (→ Page 111).
TIM-ID: 0000005447 - 009

7.10.2 Air filter – Removal and installation
Preconditions
Removing and installing air filter

1. Release clamp (2).
2. Remove air filter (3) and clamp (2) from
connecting flange of intake housing (1).
3. Verify that there are no objects in the con‐
necting flange of the intake housing (1) and
clean it.
4. Place new air filter (3) with clamp (2) onto
intake housing (1).
5. Tighten clamp (2).
TIM-ID: 0000005457 - 006

7.11 Air Intake
7.11.1 Contamination indicator – Signal ring position check (optional)
Preconditions
Checking signal ring position

1. If the signal ring is completely visible in the
observation window (2), replace air filter
(→ Page 109).
2. After installation of new filter, press reset
button (1).
Result: Engaged piston with signal ring moves back
to initial position.
TIM-ID: 0000005484 - 007

7.12 Starting Equipment
7.12.1 Starter – Condition check
Preconditions
Checking starter condition

1. Check securing screws of starter for secure seating and tighten if required.
2. Check wiring (→ Page 143).
TIM-ID: 0000000905 - 017

7.13 Lube Oil System, Lube Oil Circuit
7.13.1 Engine oil – Level check
Preconditions
Oil level check prior to engine start

1. Withdraw oil dipstick from guide tube and
wipe it.
2. Insert oil dipstick into guide tube up to the
stop, withdraw after approx. 10 seconds
and check oil level.
3. Oil level must be between "min." and "max."
marks.
4. Top up to "max." if required (→ Page 114).
5. Insert oil dipstick into guide tube up to the
stop.
Oil level check after the engine is stopped

1. 5 minutes after stopping the engine, remove oil dipstick from the guide tube and wipe it.
2. Insert oil dipstick into guide tube up to the stop, withdraw after approx. 10 seconds and check oil level.
3. Oil level must be between “min.” and "max." marks.
4. Top up to "max." if required (→ Page 114).
5. Insert oil dipstick into guide tube up to the stop.
TIM-ID: 0000000032 - 002

7.13.2 Engine oil – Change
Preconditions
☑ Engine shut down and starting disabled.
☑ Engine is at operating temperature.

Engine oil
WARNING
Hot oil.
Version with extraction equipment: Extracting engine oil

1. Position a suitable container to drain the engine oil into.
2. Extract all engine oil from oil pan using the extraction equipment.
Filling with new engine oil

1. Determine amount of engine oil required for
oil change (→ Product Summary - Technical
Data).
2. Open cover on filler neck.
3. Fill engine oil through filler neck up to
“max.” mark on oil dipstick.
4. Close cover on filler neck.
5. Check engine oil level (→ Page 113).
6. After oil change, crank engine with starting
system.
TIM-ID: 0000006159 - 002

7.14 Oil Filtration / Cooling
7.14.1 Engine oil filter – Replacement

Engine oil
Oil filter (→ Spare Parts Catalog)
Plastic ring (→ Spare Parts Catalog)
DANGER
WARNING
WARNING
Hot oil.
CAUTION
Damage to component.
Serious damage to plant!
• For filter replacement with the engine running, operate the engine at low engine load.
• The filter which is to be exchanged must be cut out for a brief period only.
TIM-ID: 0000006365 - 005

Oil filter replacement with the
engine stopped
1. Stop engine (→ Page 66) and disable en‐
gine start.
A Right filter cut out
B Both filters cut in (normal operating
position)
C Left filter cut out
3. Remove cut-out oil filter using the oil filter

wrench.
4. Clean sealing surface on connecting piece.
5. Check condition of new oil filter sealing ring
and coat it with oil.
7. Screw on and tighten new engine oil filter
by hand.
8. Replace other oil filters in the same way.
9. Switch filter to normal position.
10. After each oil change and filter replace‐
ment, crank engine with starting system
(→ Page 84).
11. Check oil level (→ Page 113).
Oil filter replacement with the engine running

1. Reduce engine speed to <1100 rpm.
2. Remove cut-out oil filter using the oil filter wrench.
3. Clean sealing surface on connecting piece.
4. Check condition of new oil filter sealing ring and coat it with oil.
6. Screw on and tighten new engine oil filter by hand.
7. Replace other oil filters in the same way.
8. Switch filter to normal position.
TIM-ID: 0000006365 - 005
9. Check oil level (→ Page 113).

7.14.2 Centrifugal oil filter – Cleaning and filter-sleeve replacement
Preconditions

Strap wrench F30379104 1
Cold cleaner (Hakutex 50) 50622 1
Filter sleeve (→ Spare Parts Catalog)
O-ring (→ Spare Parts Catalog)
O-ring (→ Spare Parts Catalog)
WARNING
Compressed air
Risk of injury!
Removing rotor of centrifugal oil

filter
1. Release nuts (3).
2. Remove housing cover (1).
3. Remove complete rotor (2) from housing.
TIM-ID: 0000006418 - 002

Cleaning centrifugal oil filter and
replacing filter sleeve
1. Remove nut, holding the rotor with a strap
wrench.
2. Remove nut (1), washer (2), rotor cap (3)

and sealing ring (4).
3. Remove sleeve (1).

4. Measure the layer thickness of the oil resi‐
due.
5. If maximum layer thickness (25 mm) is ex‐
ceeded, shorten maintenance interval.
6. Clean rotor components and remove strain‐
ers (2).
7. Wash standpipes (3) and nozzles (4) with
cleaner, blow out with compressed air.
8. Insert the new filter sleeve with the smooth
surface facing the rotor cap.
TIM-ID: 0000006418 - 002

9. Fit new sealing ring (4).
10. Set on rotor cap (3), observe marks.
11. Fit washer (2).
12. Hold rotor (new design) with strap wrench and tighten nut (1) with torque wrench to the specified torque.
Nut M18 x 1.5 Tightening torque 10 Nm
13. Hold rotor (old design) with strap wrench and tighten nut (1) with torque wrench to the specified torque.
Nut M16 x 1.5 Tightening torque 40 Nm to 50 Nm
14. Insert complete rotor (2) into the housing
and check for ease-of-movement.
15. Set housing cover (1) with new sealing ring
onto lower section, observe marks.
16. Tighten nuts (3) crosswise and evenly.
TIM-ID: 0000006418 - 002

7.15 Coolant Circuit, General, High-Temperature Circuit
7.15.1 Drain and venting points
8 V, 10 V
1 Overflow line, expan‐ 2 Filler neck

sion tank
TIM-ID: 0000006696 - 002

Free end (KGS)
1 Fuel filter vent screws 3 Raw water pump filling 5 Raw water pump drain
2 Engine coolant drain plug plug
plug 4 Measuring point, pres‐ 6 Connection for oil ex‐
sure before raw water traction
pump
TIM-ID: 0000006696 - 002

Left side
1 Engine coolant drain 2 Engine coolant drain

plug plug (M14x1.5)
TIM-ID: 0000006696 - 002

Right side
1 Engine coolant drain 3 Oil dipstick (connection

plug (M14x1.5) on left or right engine se‐
2 Oil filler neck (connec‐ lectable)
tion on left or right en‐ 4 Leak-fuel tank
gine selectable)
TIM-ID: 0000006696 - 002

Driving end (KS)
1 Engine coolant drain 2 Connection for oil ex‐

plug traction
TIM-ID: 0000006696 - 002

7.15.2 Engine coolant – Level check
Preconditions
☑ MTU Fluids and Lubricants Specification (A001061/..) is available.
WARNING
Coolant is hot and under pressure.
• Let the engine cool down.
Coolant-level check at filler neck:

1. Turn breather valve on coolant expansion
tank (→ Page 36) counterclockwise until first
stop and allow pressure to escape.
2. Continue to turn breather valve counter‐
clockwise and remove.
3. Check coolant level (coolant must be visible
at the lower edge of the cast-in eye).
Coolant-level check by means of level sensor:

1. Switch engine control system on and check display (coolant level is automatically monitored by the en‐
gine control system).
2. If required, top up with treated engine coolant (→ Page 128).
TIM-ID: 0000006765 - 001

7.15.3 Engine coolant – Change

Coolant
Engine coolant – Change

1. Drain engine coolant (→ Page 127).
2. Fill with engine coolant (→ Page 128).
TIM-ID: 0000000036 - 030

7.15.4 Engine coolant – Draining
Preconditions
WARNING
Preparatory steps
1. Provide an appropriate container to collect the coolant or
2. switch on the extraction device.
3. Switch off preheating unit.
Engine coolant – Draining

1. Turn breather valve on coolant expansion tank (→ Page 120)counterclockwise to the first stop and re‐
lease pressure.
2. Continue to turn breather valve counterclockwise and remove.
3. Draw off precipitated corrosion inhibitor oil from the expansion tank through filler neck.
4. Open drain valves or drain plugs (→ Page 120) and drain or pump off coolant.
5. Close all open drain points.
6. Set breather valve onto filler neck and close it.
TIM-ID: 0000006746 - 001

7.15.5 Engine coolant – Filling
Preconditions

Engine coolant
WARNING
CAUTION
Cold coolant in hot engine can cause thermal stress.
Formation of cracks in components!
• Fill / top up coolant only into cold engine.
Filling engine coolant

1. (→ Page 36)Turn breather valve of coolant expansion tank counterclockwise until the first stop and allow
pressure to escape.
3. Pour coolant into engine until coolant level reaches lower edge of cast-in eye of filler neck.
4. Check proper condition of breather valve and clean sealing faces.
5. Place breather valve on filler neck and close.
6. Start the engine and operate it at idle speed for some minutes.
7. Check coolant level (→ Page 125).
TIM-ID: 0000006728 - 002

7.15.6 HT coolant pump — Relief bore check
DANGER
WARNING
HT coolant pump — Relief bore

check
1. Check relief bore for oil and coolant dis‐
charge.
2. Stop engine (→ Operating instructions elec‐
tronic system) and disable engine start.
3. Clean the relief bore with a wire if it is dirty.
• Permissible engine coolant discharge: up
to 10 drops per hour;
• Permissible oil discharge: up to 5 drops
per hour.
4. If discharge exceeds the specified limits,
contact Service.
TIM-ID: 0000006803 - 002

7.15.7 Engine coolant – Sample extraction and analysis
Preconditions
☑ MTU Fluids and Lubricants Specification (A001061/..) is available.

MTU test kit 5605892099/00 1
WARNING
Engine coolant – Sample extraction and analysis

1. Turn breather valve on coolant expansion tank (→ Page 120)counterclockwise until first stop and allow
pressure to escape.
3. Draw off precipitated corrosion inhibitor oil from expansion tank and dispose of oil.
4. Draw off approx. 1 liter coolant and drain into a clean container.
5. Using the equipment and chemicals from the MTU test kit, examine coolant for:
• antifreeze concentration;
• corrosion inhibitor concentration;
• pH value.
6. Fit breather valve and close it.
7. Change engine coolant according to the coolant operating times specified in the (→ MTU Fluids and Lu‐
bricants Specifications A001061/..)(→ Page 127).
TIM-ID: 0000006774 - 001

7.15.8 Coolant filter – Replacement
Preconditions

Coolant filter (→ Spare Parts Catalog)
WARNING
Coolant filter – Replacement

1. Turn breather valve of coolant expansion
tank counterclockwise (→ Page 36) to the
first stop and allow pressure to escape.
2. Continue to turn breather valve counter‐
clockwise and remove.
3. Remove coolant filter using the oil filter
wrench.
4. Clean the sealing face on the adapter.
5. Coat sealing ring of the new coolant filter
with engine oil.
6. Install and tighten coolant filter by hand.
7. Close breather valve.
8. Check coolant level (→ Page 125).
TIM-ID: 0000006921 - 004

7.16 Raw Water Pump with Connections
7.16.1 Raw water pump – Relief bore check
DANGER
WARNING
Raw water pump – Relief bore

check
1. Check relief bore for oil and coolant dis‐
charge.
2. Stop engine (→ Page 66) and disable en‐
gine start.
3. Clean the relief bore with a wire if it is dirty.
• Permissible coolant discharge: up to 10
drops per hour;
• Permissible oil discharge: up to 5 drops
per hour.
4. If discharge exceeds the specified limits,
contact Service.
TIM-ID: 0000007284 - 001

7.17 Belt Drive
7.17.1 Drive belt – Condition check
Preconditions
☑ Guard is removed.
Drive belt – Condition check
Item Findings Action

Drive belt A Singular cracks None
Drive belt Belt is oily, shows signs of over‐ Replace (→ Page 136)
heating
Drive belt B Cracks on entire circumference
Drive belt C Chunking
TIM-ID: 0000000920 - 010

7.18 Battery-Charging Generator
7.18.1 Battery-charging generator drive – Drive belt check and adjustment
Preconditions

Assembly device F6559691 1
Preparatory steps
1. Remove limit switch (4).
2. Remove indicator (1).
3. Remove screws (3) of protective cover (2).
4. Remove protective cover.
5. Check drive belt condition (→ Page 133).
Belt drive – Checking distance

1. Measure distance (A) with assembly de‐
vice.
2. If measured value of distance (A) is not
within the tolerance of 98 mm ± 1.5 mm, re‐
adjust belt tension.
TIM-ID: 0000007388 - 004

Adjusting belt tension
1. Hold adjustment lever (2) at square (5).
2. Rotate adjusting lever until drive belt (4) is released.
3. Loosen screws (1) and (3).
4. Use assembly device to adjust distance (A) by turning adjustment lever (2).
5. Tighten screws (1) and (3).
6. Measure distance (A) with assembly device.
Final steps
1. Install protective cover (2).
2. Install securing screws (3) of protective cov‐
er (2).
3. Install indicator (1).
4. Install limit switch (4).
TIM-ID: 0000007388 - 004

7.18.2 Battery-charging generator drive – Drive belt replacement
Preconditions

Mandrel 8205892861/08 1
Preparatory steps
1. Remove safety equipment (if fitted).
2. Remove screws of protective cover (engine free end).
3. Remove protective cover.
Drive belt – Replacement

1. Hold adjusting lever at square.
2. Rotate adjusting lever until drive belt is released.
3. Use mandrel to lock adjusting lever in position.
4. Remove drive belt.
5. Check cleanness of belt pulleys.
6. Fit new drive belt.
7. Remove mandrel.
Final steps
1. Install protective cover.
2. Install screws of protective cover.
3. Install safety equipment (if fitted).
4. Check function of safety equipment (if fitted).
TIM-ID: 0000007424 - 003

7.19 Fuel Supply System
7.19.1 Water drain valve – Check
Water drain valve – Check

1. Open water drain valve.
2. Check water outlet for obstructions.
3. Close water drain valve.
TIM-ID: 0000007733 - 007

7.19.2 Differential pressure gauge – Check
WARNING
• Do not smoke.
Checking differential pressure gauge

2. Set the alarm points at the differential pressure gauge to zero.
Result: Alarm is initiated with preset delay.
3. Reset the alarm points at the differential pressure gauge to the specified values.
TIM-ID: 0000007737 - 005

7.19.3 Water level probe (3-in-1 rod electrode) – Check
Preconditions
☑ System is put out of operation and emptied.
WARNING
• Do not smoke.
Checking water level probe (3-in-1 rod electrode)

1. Disconnect connector from water level probe.
2. Unscrew water level probe.
4. Immerse water level probe into a tank filled with water until water level reaches the thread.
5. Switch system on.
Result: Water drain valve opens.
6. Leave water level probe in tank.
Result: Alarm must be triggered with the preset delay.
7. Switch off the system.
9. Remove water level probe from tank.
10. Screw in water level probe.
11. Connect connector for water level probe.
12. Fill and vent the system then put it into operation.
TIM-ID: 0000007739 - 007

7.19.4 Pump capacity – Check
WARNING
• Do not smoke.
Checking pump capacity

1. Install suitable pressure gauge at the neck of the intake side of the pump.
2. Check pump pressure.
a) Switch on fuel treatment system (→ Page 64).
Note: The pressure limiting valve at the pump might respond and open. Audible noise is caused by overflowing
fuel and can be disregarded.
b) Close ball valve at the outlet of the fuel treatment system.
c) Check pressure at the pressure gauge in the inlet to the fuel treatment system and note it.
3. Check pump pressure with reduced suction.
a) Reduce suction pressure of pump to -0.8 bar with the shutoff valve at the pump intake side.
b) Check pressure at the pressure gauge in the inlet to the fuel treatment system and note it.
c) Open ball valve at inlet and outlet of fuel treatment system.
4. Calculate wear limit.
Example:
Measured value (normal condition). 3 bar
Measured value (reduced suction condition). 2.6 bar
If the measured value (reduced suction condition) is 10% lower than the measured value (normal con‐
dition), the wear limit is reached. Repair pump (contact Service).
TIM-ID: 0000007740 - 007

7.19.5 Coalescer filter element – Replacement
Preconditions
☑ System is switched off and starting disabled.

Ratchet adapter F30027339 1
Diesel fuel
Engine oil
Coalescer filter element (→ Spare Parts Catalog)
WARNING
• Do not smoke.
CAUTION
Contamination of components.
• Observe manufacturer's instructions.
• Check components for special cleanness.
CAUTION
Incorrect installation of components and lines.
• Ensure that components/lines are installed so that they are never under tension or strain.
• Ensure correct installation position of components.
Coalescer filter element –

Replacement
1. Close ball valve at the inlet and outlet of the
fuel treatment system.
2. Open drain valve.
3. Drain fuel.
4. Close drain valve.
5. Remove nut (9) with washer (2).
7. Remove cover with gasket (10).
TIM-ID: 0000007735 - 007
8. Remove nut (3), washer (8) and end

plate (7).
9. Remove coalescer filter element (4).
10. Catch fuel as it runs out.
11. Clean housing with a non-linting cloth, rinse
with fuel if required.
12. Check housing for corrosion.
13. Clean housing sealing surfaces.
14. Install coalescer filter element.
15. Install end plate (7), washer (8) and nut (3).

16. Tighten nut (3) to specified tightening torque using a torque wrench.
Nut M16 Tightening torque (Engine oil) 30 Nm +3 Nm
17. Fit gasket (10).
18. Install cover.
19. Install screw (1), washer (2) and nut (9).
20. Tighten nut (9).
21. Open ball valve at the inlet and outlet of the fuel treatment system.
Result: The fuel treatment system is ready for operation.
TIM-ID: 0000007735 - 007

7.20 Wiring (General) for Engine/Gearbox/Unit
7.20.1 Engine wiring – Check
Preconditions

Isopropyl alcohol X00058037 1
Engine wiring – Check

1. Check securing screws of cable clamps on engine and tighten loose threaded connections.
2. Ensure that cables are fixed in their clamps and cannot swing freely.
3. Check that cable ties are firm, tighten loose cable ties.
4. Replace faulty cable ties.
5. Visually inspect the following electrical line components for damage:
• connector housings;
• contacts;
• sockets;
• cables and terminals;
• plug-in contacts.
6. (→ Contact Service) if cable conductors are damaged.
Note: Close male connectors that are not plugged in with the protective cap supplied.
7. Clean dirty connector housings, sockets and contacts with isopropyl alcohol.
8. Ensure that all sensor connectors are securely engaged.
TIM-ID: 0000000029 - 018

7.21 Accessories for (Electronic) Engine Governor / Control
System
7.21.1 Engine governor and connectors – Cleaning
Preconditions

Note: Always use test connectors to enter the connectors. Never use test leads for this purpose.Otherwise the
contacts could be bent.
Engine governor and connectors – Cleaning

1. Remove coarse dirt from housing surface with isopropyl alcohol.
2. Remove dirt from connector and cable surfaces with isopropyl alcohol.
3. Check legibility of cable labels. Clean or replace illegible labels.
Cleaning severely contaminated connectors on the engine governor

Note: Seal unused connectors with the supplied protective cap.
1. Release the latch and pull off connectors.
2. Clean connector housings, connector socket housings and all contacts with isopropyl alcohol.
3. When connectors, sockets and all contacts are dry: Fit connectors and lock them.
TIM-ID: 0000000047 - 009

7.21.2 Engine monitoring unit and connectors – Cleaning
Preconditions

Connector pliers 0135315483 1
Engine monitoring unit and

connectors – Cleaning
1. Remove coarse dirt from housing surface
with isopropyl alcohol.
2. Remove dirt from surface of connectors (1),
connector sockets and shrink sleeves (2)
using a cloth moistened with isopropyl alco‐
hol.
3. Check legibility of cable labels. Clean or re‐
place illegible labels.
Cleaning severely contaminated

EMU connectors
1. Use connector pliers (2) to disengage bayo‐
net union nut (4) and withdraw connector
(3).
2. Clean connector housings, connector sock‐
et housings (1) and all contacts with iso‐
propyl alcohol.
3. When connectors, sockets and all contacts
are dry: Fit connectors and check plug con‐
nections on EMU (→ Page 147).
TIM-ID: 0000008391 - 006

7.21.3 Engine governor – Checking plug-in connections
Preconditions
Note: Always use test connectors to enter the connectors. Never use test leads for this purpose.Otherwise the
contacts could be bent.
Checking plug-in connections on engine governor

1. Check all plug-in connections for secure seating.
2. Latch connectors if loose.
TIM-ID: 0000000048 - 005

7.21.4 Engine monitoring unit – Plug connection check
Preconditions

Connector pliers 0135315483 1
Checking engine monitoring unit

plug connections
1. Use connector pliers (3) to make certain
that all engine monitoring unit plug connec‐
tions are securely seated.
2. Tighten loose bayonet union nuts (2) with
connector pliers (3) by turning them clock‐
wise until they lock into place.
3. Make sure that unassigned sockets are
closed off with cover caps.
4. If bayonet couplings are defective, contact
Service.
TIM-ID: 0000008394 - 003

7.21.5 Engine governor – Carry out self-test
DANGER
Electrical voltage.
Risk of serious injury - danger to life!
• Make certain that the power supply to the engine is switched off before starting to work. Ensure
that the power supply cannot be switched on unintentionally!
Carrying out self-test

1. Switch off power supply to system.
2. Remove connectors X1, X2 and X4 from
the engine governor.
a) Release lock (3) of connectors (2).
b) Unplug connector (2).
3. Switch on power supply
Result: • The engine governor is operable if the di‐
agnostic lamp (1) changes to continuous
illumination within 30 seconds after pow‐
er has been switched on.
• If the diagnostic lamp (1) flashes after 30
seconds, replace engine governor and
(→ contact Service).
• Check the power supply if the diagnostic
lamp remains dark.
4. Switch off power supply.
5. Refit connectors X1, X2 and X4 on engine
governor.
a) Plug in connector (2).
b) Lock connectors.
TIM-ID: 0000008482 - 002

7.21.6 ECU 7 engine governor – Removal and installation
Preconditions
CAUTION
Wrong engine governor installed.
Engine damage!
• When reassembling an engine, make sure that the governor with the data record for the given
engine is installed.
Removing engine governor from

engine
1. Note or mark assignment of cables and
connectors.
2. Remove all screws (2).
3. Undo latches (3) of the connectors.
4. Remove all connectors.
6. Take off engine governor.
Installing engine governor on engine

1. Install in reverse order. In doing so, ensure correct assignment of connectors and sockets.
2. Check rubber mount before installation.
Result: If the rubber mount is porous or defective, replace it.
TIM-ID: 0000000049 - 005

7.21.7 Engine monitoring unit – Removal and installation
Preconditions
CAUTION
Wrong engine governor installed.
Engine damage!
• When reassembling an engine, make sure that the governor with the data record for the given
engine is installed.
Removing engine governor with

engine monitoring unit from engine
1. Note or mark assignment of cables and
plugs.
2. Remove all screws (2).
3. Release lock (3) of connectors..
4. Remove all connectors.
6. Remove engine governor (1) with engine
monitoring unit (4).
Removing engine monitoring unit

1. Unscrew screws on base of EMU (4).
2. Remove EMU (4) with engine governor (1).
Installing engine monitoring unit

1. Place EMU (4) in position at engine governor (1).
2. Screw in and tighten screws on base of EMU (4).
Installing engine governor with engine monitoring unit on engine

1. Install in reverse order. Ensure correct assignment of plugs and sockets.
2. Check resilient mount before installing.
Result: If resilient mount is porous or defective then replace it.
TIM-ID: 0000008493 - 002

8 Appendix A
8.1 Abbreviations
Abbrevia‐ Meaning Explanation

tion
ADEC Advanced Diesel Engine Control Engine governor
AL Alarm Alarm (general)
ANSI American National Standards Institute Association of American standardization organiza‐
tions
ATL Abgasturbolader Exhaust turbocharger (ETC)
BR Baureihe Series
BV Betriebsstoffvorschrift MTU Fluids and Lubricants Specifications, Publica‐
tion No. A01061/..
CAN Controller Area Network Data bus system, bus standard
CCG Cross Connection Gear Transfer gearbox
CODAG Combined Diesel (engine) And Gas
(turbine propulsion)
CPP Controllable Pitch Propeller
DAG Diesel (engine) And Gas (turbine)
DE Diesel Engine
DIN Deutsches Institut für Normung e. V. At the same time identifier of German standards
(DIN = “Deutsche Industrie-Norm”)
DIS Display unit
DL Default Lost Alarm: CAN bus missing
ECS Engine Control System
ECS-UNI Engine Control System UNIversal
ECU Engine Control Unit Engine governor
EDM Engine Data Module
EMU Engine Monitoring Unit
ETK Ersatzteilkatalog Spare Parts Catalog (SPC)
FPP Fixed Pitch Propeller
GCU Gear Control Unit
GMU Gear Monitoring Unit
TIM-ID: 0000002049 - 005
GT Gas Turbine
HAT Harbor Acceptance Test
HI High Alarm: Measured value exceeds 1st maximum limit
HIHI High High Alarm: Measured value exceeds 2nd maximum lim‐
it value
HT High Temperature
ICFN ISO – Continuous rating – Fuel stop Power specification in accordance with DIN-ISO
power – Net 3046-7
M015630/04E 2012-07 | Appendix A | 151

tion
IDM Interface Data Module
IMO International Maritime Organization
ISO International Organization for Stand‐ International umbrella organization for all national
ardization standardization institutes
KGS Kraftgegenseite Engine free end in accordance with DIN ISO 1204
KS Kraftseite Engine driving end in accordance with DIN ISO
1204
LCD Liquid Crystal Display, Liquid Crystal
Device
LCU Local Control Unit LOP subassembly
LED Light Emitting Diode
LMU Local Monitoring Unit LOP subassembly
LO Low Alarm: Measured value lower than 1st minimum
limit value
LOLO Low Low Alarm: Measured value lower than 2nd minimum
limit value
LOP Local Operating Panel Control console, control panel
LOS Local Operating Station
MCS Monitoring and Control System
MG Message
MPU Microprocessor Unit, Microprocessing
Unit
MRG Main Reduction Gear
OT Oberer Totpunkt Top Dead Center (TDC)
P-xyz Pressure-xyz Pressure measuring point xyz
PAN Panel Control panel
PCU Propeller Control Unit
PIM Peripheral Interface Module
PT Power Turbine
RCS Remote Control System
RL Redundancy Lost Alarm: Redundant CAN bus missing
SAE Society of Automotive Engineers U.S. standardization organization
SAT Sea Acceptance Test
SD Sensor Defect Alarm: Sensor failure
TIM-ID: 0000002049 - 005
SDAF Shut Down Air Flaps Emergency-air shutoff flap(s)

SOLAS International Convention for the Safe‐
ty of Life at Sea
SS Safety System Safety system alarm
SSK Schnellschlussklappe(n) Emergency air shut-off flaps
SSS Synchronized Self-Shifting (clutch)
STBD Starboard
T-xyz Temperature-xyz Temperature measuring point xyz
152 | Appendix A | M015630/04E 2012-07

tion
TD Transmitter Deviation Alarm: Deviation in transmitter values
UT Unterer Totpunkt Bottom Dead Center (BDC)
VS Voith Schneider Voith Schneider drive
WJ Water jet Water jet drive
WZK Werkzeugkatalog Tool Catalog (TC)
ZKP Zugehörigkeit-Kategorie-Parameter Assignment category parameter; number scheme
for signals from the ADEC engine governor
TIM-ID: 0000002049 - 005
M015630/04E 2012-07 | Appendix A | 153

8.2 Standard tools – Overview
Part No. Designation Qty.

Use
8205891159/00 General tools kit 1
TIM-ID: 0000003192 - 001
154 | Appendix A | M015630/04E 2012-07

8.3 MTU contact persons/service partners
Our worldwide sales network with its subsidiaries, sales offices, representatives and customer service
centers ensures fast and direct support on site and the high availability of our products.
Local support
Experienced and qualified specialists place their knowledge and expertise at your disposal.
For locally available support, go to the MTU Internet site: http://www.mtu-online.com
24h hotline
With our 24h hotline and the outstanding flexibility of our service staff, we are always ready to assist you
– either during operation, for preventive maintenance, corrective work in case of malfunction or changed
operating conditions, or for spare parts supply.
Your contact at Headquarters: Service-support@mtu-online.com
Spare parts service

Fast, simple and correct identification of spare parts for your drive system or vehicle fleet. The right spare
part at the right time at the right place.
With this aim in mind, we can call on a globally networked spares logistics system, a central warehouse
at headquarters and on-site stores at our subsidiary companies, agencies and service workshops.
Your contact at Headquarters:
E-mail: spare.parts@mtu-online.com
Phone: +49 7541 908555
Fax: +49 7541 908121
TIM-ID: 0000000873 - 014
M015630/04E 2012-07 | Appendix A | 155

9 Appendix B
9.1 Special Tools
Alignment device
Part No.: F6790507
Qty.: 1
Used in: 7.6.2 Injector – Removal and installation (→ Page 97)
Angular screw driver

Part No.: F30002816
Qty.: 1
Used in: 7.5.1 Valve clearance – Check and adjustment (→ Page
92)
Assembly device
Part No.: F6559691
Qty.: 1
Used in: 7.18.1 Battery-charging generator drive – Drive belt
check and adjustment (→ Page 134)
Barring tool
Part No.: F6783914
Qty.: 1
Used in: 7.2.1 Engine – Barring manually (→ Page 83)
Qty.: 1
DCL-ID: 0000008418 - 004

92)
156 | Appendix B | M015630/04E 2012-07

Box wrench adapter
Part No.: F30451199
Qty.: 1
Centering device
Part No.: F6783025
Qty.: 1
Used in: 7.5.2 Cylinder-head cover – Removal and installation (→
Page 95)
Connector pliers
Part No.: 0135315483
Qty.: 1
Used in: 7.21.2 Engine monitoring unit and connectors – Clean‐
ing (→ Page 145)
Qty.: 1
Used in: 7.21.4 Engine monitoring unit – Plug connection check
(→ Page 147)
Double box wrench

Part No.: F30002800
Qty.: 1
92)
DCL-ID: 0000008418 - 004
M015630/04E 2012-07 | Appendix B | 157

Double box wrench
Part No.: F30011450
Qty.: 1
Feeler gauge
Part No.: Y4345893
Qty.: 1
92)
Mandrel
Part No.: 8205892861/08
Qty.: 1
Used in: 7.18.2 Battery-charging generator drive – Drive belt re‐
placement (→ Page 136)
Measuring device
Part No.: Y4345888
Qty.: 1
92)
DCL-ID: 0000008418 - 004
158 | Appendix B | M015630/04E 2012-07

MTU test kit
Part No.: 5605892099/00
Qty.: 1
Used in: 7.15.7 Engine coolant – Sample extraction and analysis
(→ Page 130)
Oil filter wrench

Part No.: F30379104
Qty.: 1
Used in: 7.8.1 Fuel filter – Replacement (→ Page 100)
Qty.: 1
Used in: 7.14.1 Engine oil filter – Replacement (→ Page 115)
Qty.: 1
Used in: 7.15.8 Coolant filter – Replacement (→ Page 131)
Open end wrench bit

Part No.: F30025897
Qty.: 1
Puller
Part No.: F6790629
Qty.: 1
DCL-ID: 0000008418 - 004
M015630/04E 2012-07 | Appendix B | 159

Ratchet
Part No.: F30006212
Qty.: 1
Used in: 7.2.1 Engine – Barring manually (→ Page 83)
Qty.: 1
92)
Ratchet
Part No.: F30027340
Qty.: 1
Used in: 7.4.2 Crankcase breather – Oil separator element re‐
placement, diaphragm check and replacement (→ Page
90)
Ratchet adapter
Part No.: F30027339
Qty.: 1
Used in: 7.19.5 Coalescer filter element – Replacement (→ Page
141)
Rigid endoscope
Part No.: Y20097353
Qty.: 1
Used in: 7.3.1 Cylinder liner – Endoscopic examination (→ Page
85)
DCL-ID: 0000008418 - 004
160 | Appendix B | M015630/04E 2012-07

Socket wrench
Part No.: F30030450
Qty.: 1
92)
Socket wrench
Part No.: 0005896803/00
Qty.: 1
Steam jet cleaner

Part No.: -
Qty.: 1
Used in: 4.13 Plant cleaning (→ Page 70)
Strap wrench
Part No.: F30379104
Qty.: 1
Used in: 7.14.2 Centrifugal oil filter – Cleaning and filter-sleeve
replacement (→ Page 117)
Torque wrench, 10-60 Nm

Part No.: F30510423
Qty.: 1
92)
DCL-ID: 0000008418 - 004
M015630/04E 2012-07 | Appendix B | 161

Part No.: F30027336
Qty.: 1
Used in: 7.19.5 Coalescer filter element – Replacement (→ Page
141)

Part No.: F30027336
Qty.: 1
Used in: 7.4.2 Crankcase breather – Oil separator element re‐
placement, diaphragm check and replacement (→ Page
90)
DCL-ID: 0000008418 - 004
162 | Appendix B | M015630/04E 2012-07

9.2 Consumables
Cleaner (Hakupur 312)
Part No.: 30390
Qty.: 1
Used in: 4.13 Plant cleaning (→ Page 70)
Cold cleaner (Hakutex 50)

Part No.: 50622
Qty.: 1
Used in: 7.14.2 Centrifugal oil filter – Cleaning and filter-sleeve replacement (→ Page 117)
Coolant
Part No.:
Qty.:
Used in: 7.15.3 Engine coolant – Change (→ Page 126)
Diesel fuel
Part No.:
Qty.:
Qty.:
Used in: 7.8.3 Fuel prefilter – Draining (→ Page 103)
Qty.:
Used in: 7.8.4 Fuel prefilter – Flushing (→ Page 104)
Qty.:
Used in: 7.8.5 Fuel prefilter – Filter element replacement (→ Page 106)
Qty.:
Used in: 7.19.5 Coalescer filter element – Replacement (→ Page 141)
Engine coolant
Part No.:
Qty.:
Used in: 7.15.5 Engine coolant – Filling (→ Page 128)
Engine oil
Part No.:
Qty.:
DCL-ID: 0000008418 - 004
Used in: 7.4.2 Crankcase breather – Oil separator element replacement, diaphragm check and
Qty.:
Qty.:
Used in: 7.13.2 Engine oil – Change (→ Page 114)
Qty.:
Qty.:
M015630/04E 2012-07 | Appendix B | 163

fuel
Part No.:
Qty.:
Used in: 7.4.1 Crankcase breather – Cleaning oil pre-separator element (→ Page 89)
Grease (Kluthe Hakuform 30-10/Emulgier)

Part No.: X00029933
Qty.: 1
Isopropyl alcohol
Part No.: X00058037
Qty.: 1
Used in: 7.20.1 Engine wiring – Check (→ Page 143)
Qty.: 1
Used in: 7.21.1 Engine governor and connectors – Cleaning (→ Page 144)
Qty.: 1
Used in: 7.21.2 Engine monitoring unit and connectors – Cleaning (→ Page 145)
Shield A4
Part No.: 735233000100
Qty.: 5
Used in: 7.1.2 SOLAS shielding – Installation as per MTN 5233 (→ Page 82)
Shield A5
Part No.: 735233000101
Qty.: 7
Shield A7
Part No.: 735233000103
Qty.: 6
Shield A8
Part No.: 735233000104
Qty.: 2
DCL-ID: 0000008418 - 004
164 | Appendix B | M015630/04E 2012-07

9.3 Spare Parts
Air filter
Part No.:
Qty.:
Used in: 7.10.1 Air filter – Replacement (→ Page 109)
Coalescer filter element

Part No.:
Qty.:
Coolant filter
Part No.:
Qty.:
Used in: 7.15.8 Coolant filter – Replacement (→ Page 131)
Diaphragm
Part No.:
Qty.:
Easy-change filter
Part No.:
Qty.:
Filter element
Part No.:
Qty.:
Qty.:
Filter sleeve
Part No.:
DCL-ID: 0000008418 - 004
Qty.:
M015630/04E 2012-07 | Appendix B | 165

Gasket
Part No.:
Qty.:
Qty.:
Used in: 7.5.2 Cylinder-head cover – Removal and installation (→ Page 95)
Qty.:
Injector
Part No.:
Qty.:
Used in: 7.6.1 Injector – Replacement (→ Page 96)
O-ring
Part No.:
Qty.:
Qty.:
Oil filter
Part No.:
Qty.:
Plastic ring
Part No.:
Qty.:
Seal
Part No.:
Qty.:
Used in: 7.8.3 Fuel prefilter – Draining (→ Page 103)
Qty.:
Used in: 7.8.4 Fuel prefilter – Flushing (→ Page 104)
Qty.:
DCL-ID: 0000008418 - 004
166 | Appendix B | M015630/04E 2012-07

9.4 Index
10V 2000 M72 engine data: Engine-mounted heat ex‐ D
changer 52 Differential pressure gauge
10V 2000 M72 engine data: Separate heat exchanger 49 – Check 138
8V 2000 M72 engine data : Separate heat exchanger 43 Drain and venting points 120
8V 2000 M72 engine data: Engine-mounted heat ex‐ Drive belt
changer 46 – Condition check 133
A E
Abbreviations 151 ECU 7 engine governor
Actuators – Removal and installation 149
– Overview 38 Emergency stop 67
After stopping the engine 68 Engine
Air filter – Barring manually 83
– Removal and installation 110 – layout 36
– Replacement 109 – Main dimensions 56
Auxiliary materials 15 – Putting the engine into operation (out of service > 3
months) 57
B
– Start 63
Battery-charging generator drive – Wiring check 143
– Adjustment 134 Engine coolant
– Check 134 – Change 126
Battery-charging generator drive – Filling 128
– Drive belt Engine coolant – Draining 127
– Replacement 136 Engine coolant – Level check 125
Engine coolant – Sample extraction and analysis 130
C
Engine governor
Centrifugal oil filter – Carry out self-test 148
– Cleaning 117 – Checking plug-in connections 146
– Filter-sleeve replacement 117 – Cleaning 144
Checks Engine monitoring unit
– Prior to start-up 60 – Cleaning 145
Coalescer filter element – Plug connection check 147
– Replacement 141 – Removal and installation 150
Connectors Engine oil
– Cleaning 144, 145 – Change 114
Contact persons 155 Engine oil filter
Contamination indicator – Replacement 115
– Signal ring position check 111 Engine oil level
Coolant – Check 113
– Filter Engine side
– Replacement 131 – Designation 29
Coolant filter Engine wiring
– Replacement 131 – Check 143
Crankcase breather Engine – Barring with starting system 84
– Cleaning oil pre-seperator element 89 Environmental protection 15
DCL-ID: 0000008418 - 004
– Diaphragm check 90
– Oil separator element replacement 90 F
Cylinder Filter
– Designation 29 – Coalescer Element
Cylinder liner – Replacement 141
– Endoscopic examination 85 – Coolant
– Instructions and comments on endoscopic and visual – Replacement 131
examination 87 Fire prevention 15
Cylinder-head cover – Removal and installation 95 Firing order 55
Fluids and lubricants 15
M015630/04E 2012-07 | Appendix B | 167

Fuel Product description 30
– Prefilter Pump capacity
– Differential pressure gauge - Check and adjust‐ – Check 140
ment 102 Putting into operation
– Draining 103 – Fuel treatment system 61
– Filter element replacement 106 Putting the engine into operation after scheduled out-of-
– Treatment system service period 58
– Troubleshooting 72
– treatment system R
– Shutdown 69 Raw water pump – Relief bore check 132
– Switching on 64 Repair work
Fuel filter – Safety regulations 12
– Replacement 100
Fuel prefilter S
– Differential pressure gauge Safety instructions 17
– Check and adjustment 102 Safety regulations 11, 12
– Draining 103 Sensors
– Filter element – Overview 38
– Replacement 106 Service partners 155
Fuel prefilter – Flushing 104 SOLAS shielding
Fuel system – Venting 99 – Installation as per MTN 5233 82
Fuel treatment system – Installation locations 76
– Putting into operation 61 Spare parts service 155
– Shutdown 69 Standard tools – Overview 154
– Switching on 64 Starter
– Condition check 112
G Startup
General conditions 7 – Safety regulations 11
Stopping the engine 66
H
Hotline 155 T
HT coolant pump Tasks
– Relief bore check 129 – After extended out-of-service periods 59
Tasks after extended out-of-service periods (>3 weeks)
I 59
Injector Tightening specifications
– Removal and installation 97 – screws, nuts and bolts 18
Injector – Replacement 96 Transport 9
Injectors Troubleshooting 73
– Overview 38 – Fuel treatment system 72
Intercooler – Checking condensate drain line for coolant
discharge and obstruction 108 V
Valve clearance
M – Check and adjustment 92
Maintenance schedule
– Maintenance task reference table [QL1] 71 W
Maintenance work Water drain valve
– Safety regulations 12 – Check 137
DCL-ID: 0000008418 - 004
MTU contact persons 155 Water level probe (3-in-1 rod electrode)
– Check 139
O Wiring - engine
Operation – Check 143
– Safety regulations 11
Operational checks 65
P
Personnel and organizational requirements 8
Plant
– Cleaning 70
168 | Appendix B | M015630/04E 2012-07

Operating Instructions: Diesel Engine 8 V 2000 M72 10 V 2000 M72

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Operating Instructions

4 Operation 7.4.2 Crankcase breather – Oil separator element

M015630/04E 2012-07 | Table of Contents | 5

7.7 Fuel System 99 7.18 Battery-Charging Generator 134

7.15 Coolant Circuit, General, High-

6 | Table of Contents | M015630/04E 2012-07

M015630/04E 2012-07 | Safety | 7

Working clothes and protective equipment

TIM-ID: 0000000874 - 018

8 | Safety | M015630/04E 2012-07

Transport without flange-mounted gearbox

A Max. permissible diago‐

M015630/04E 2012-07 | Safety | 9

Illustration is applicable to 8/10V 2000M engines

Setting the engine down after transport

Only set down engine on a firm, level surface.

10 | Safety | M015630/04E 2012-07

Safety precautions when putting the equipment into operation

Safety regulations for equipment operation

Operation of electrical equipment

M015630/04E 2012-07 | Safety | 11

Safety regulations for maintenance and repair work

12 | Safety | M015630/04E 2012-07

Hydraulic installation and removal

Working on electrical/electronic assemblies

Working with laser equipment

M015630/04E 2012-07 | Safety | 13

TIM-ID: 0000000879 - 023

14 | Safety | M015630/04E 2012-07

Environmental protection and disposal

Auxiliary materials, fluids and lubricants

M015630/04E 2012-07 | Safety | 15

Paints and lacquers

Acids and alkaline solutions

• Rinse eyes immediately with eyedrops or clean tap water.

16 | Safety | M015630/04E 2012-07

M015630/04E 2012-07 | Safety | 17

M2 x 1.5 390 550 350 520

18 | General Information | M015630/04E 2012-07

M22 x 1.5 560 675

M015630/04E 2012-07 | General Information | 19

Tightening torques for plug screws as per MTN 5183-1 standard

TIM-ID: 0000002333 - 010

20 | General Information | M015630/04E 2012-07

M33 x 2 160 160

M015630/04E 2012-07 | General Information | 21

Tightening torques for banjo screws as per MTN 5183-2 standard

TIM-ID: 0000002333 - 010

22 | General Information | M015630/04E 2012-07

Tightening torques for steel banjo screws

MA= tightening torques

Tightening torques for copper-aluminum alloy banjo screws

M015630/04E 2012-07 | General Information | 23

MA= tightening torques

24 | General Information | M015630/04E 2012-07

Thread Torque (Nm) + 10%

M015630/04E 2012-07 | General Information | 25

Thread Torque (Nm) + 10%

26 | General Information | M015630/04E 2012-07

M015630/04E 2012-07 | General Information | 27

Sealing head with BSP union nut

28 | General Information | M015630/04E 2012-07

1 Left engine side 3 Right engine side